FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
AND
THE PATENTS RULES, 2003
COMPLETE
SPECIFICATION
(See section 10; rule 13)
TITLE OF THE INVENTION
“GENSET CONTROLLER UNIT AND METHOD FOR INTEGRATED HANDLING OF
MULTIPLE GENSETS WITH DIFFERENT OPERATIONAL REQUIREMENTS”
APPLICANT
KIRLOSKAR OIL ENGINES LIMITED
of Laxmanrao Kirloskar Road, Khadki, Pune-411003, Maharashtra, India;
Nationality: India
The following specification particularly describes
the invention and the manner
in which it is to be performed
2
GENSET CONTROLLER UNIT AND METHOD FOR INTEGRATED HANDLING OF
MULTIPLE GENSETS WITH DIFFERENT OPERATIONAL REQUIREMENTS
TECHNICAL FIELD
5
[001] The present invention in general relates controlling of gensets. More
specifically, it pertains to a genset controller unit (GCU) and method for integrated
handling of multiple gensets with different operational requirements for power
generation application.
10
BACKGROUND OF THE INVENTION
[002] Generator sets, often referred to as "gensets", are widely used for power
generation application to provide electric power, especially in areas that are far from
15 or not connected to a power grid. The genset typically includes an engine coupled to
an alternator. The alternator converts rotational energy from the engine into
electrical energy to generate electric power. Such gensets are utilized in many
locations where mains supply of electricity is unavailable or as a back-up to mains
supply of electricity where supplies are unreliable. The gensets can vary from its
20 different ratings in electrical power output from approx. 5kVA up to around
I000kVA.
[003] A genset controller typically controls the operation of the genset,
including the operation of the engine and the alternator of the genset. Different types
25 of gensets are used for power applications with various constraints and
requirements, and some types of the gensets include, but not limited to, diesel
generators (DG), natural gas generators, propane generators, gasoline generators
and hybrid generators. Further, these gensets can also be a mechanical type of
generator and an electronic type of generator.
30
3
[004] Many gensets are employed with standard configurations and options,
but in some circumstances it is also possible to design genset controllers that could
control and operate with multiple gensets, including gensets designed and
manufactured by different companies with different setting configurations and
5 options. Sometimes the gensets with different power ratings can be replaced with
the existing one and multiple gensets with different ratings can also be used for the
power applications. In such situation, different genset controllers are in place to
handle each of the gensets based on its operation parameters and power ratings.
Accordingly, the genset controllers are evolved to improve and automate various
10 control and monitoring capabilities in the power application to meet the
requirements of different gensets.
[005] In many instances, different types of genset controllers are used for
controlling these different types of gensets to ensure the compatibility in working
15 with the gensets and its components. Also, the genset controllers have to be
compatible with different electronic control units (ECU) associated with the gensets.
Further, while replacing anyone of the existing genset with different type and power
rating of it, still it may require to replace the genset controller as well if such specific
genset controller are not previously in place. This can lead to operate multiple genset
20 controllers while using different types of gensets in place, which results in
interruption of genset operation due to non-synchronization of multiple gensets and
multiple genset controllers, and also results in space utilization to accommodate
multiple genset controllers. Thus, it is still a problem and cumbersome in handling
the incompatibility between the gensets and the genset controllers of different
25 types.
[006] US6351692B1 discloses a method and apparatus for configuring a genset
controller for operation with particular gensets. It specifically defines a genset
controller that is configurable for controlling a variety of types of gensets. The genset
30 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
4
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 user5 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.
[007] US6555929B1 discloses a method and apparatus for controlling a genset
10 having an engine and an alternator in order to prevent an excessive change in a
speed of the engine because of a sudden change in a load on the alternator. The
method includes obtaining a first measured value of an actual AC output power of
the alternator at a genset controller during a first time period, and obtaining a
second measured value of the actual AC output power of the alternator at the genset
15 controller during a second time period. The method further includes determining at
the genset controller a first output power based upon at least the first measured
value, and a second output power based upon at least the second measured value.
The method additionally includes determining at the genset controller, based upon
the first output power and the second output power, whether the actual AC output
20 power has changed in an amount greater than a first threshold, and providing a first
control signal from the genset controller to the genset causing a position of a throttle
to be modified when it is determined that the actual AC output power has changed
in an amount greater than the first threshold.
25 [008] However, these conventional arts are still not capable of handling of
different types of gensets with different power ratings and sources for power
generation application, i.e. the conventional arts require different ranges of
controllers with different sources to handle different gensets, which is cumbersome
and also increases overall costing in genset power applications. Thus, the variety of
30 types and configurations of, and options available on, different gensets has increased
such that it is becoming a need to design an improved genset controller with all
5
combined features integrated to get the uniformity in the system. Thus, there is a
constant need for the development of advanced controllers which plays a very
important role in reliable and intelligent control of a genset system.
5 [009] Therefore, it is desirable to have all possible options, tailored and inhouse genset controller unit that is compatible with various gensets operated with
different power ratings, sources, configurations and operational topology, which can
address and overcome the above mentioned technical problems and shortcomings
of the existing and conventional genset control systems.
10
SUMMARY OF THE INVENTION
[0010] The following presents a simplified summary of the invention in order to
provide a basic understanding of some aspects of the invention. This summary is not
15 an extensive overview of the present invention. It is not intended to identify the
key/critical elements of the invention or to delineate the scope of the invention. Its
sole purpose is to present some concept of the invention in a simplified form as a
prelude to a more detailed description of the invention presented later.
20 [0011] An object of the present invention is to provide a genset controller unit
(GCU), which is capable of achieving integrated handling of multiple gensets with
different operational requirements for power generation application in an efficient,
secure and cost effective manner.
25 [0012] Another object of the present invention is to provide a genset controller
unit (GCU), which is flexible and compatible with any gensets of different power
ratings, sources, configurations and operational topology without increasing overall
costing in genset power applications.
30 [0013] Yet another object of the present invention is to provide a genset
controller unit (GCU), which facilitates easy connectivity and easy modularity with
6
any gensets for better features and offerings to cover all requirements of customers
and genset market.
[0014] Yet another object of the present invention is to provide a method for
5 integrated handling of multiple gensets with different operational requirements for
power generation application, which achieves faster analysis and cost effective
solution to handle various gensets of different ratings and operating features.
[0015] According to first embodiment of present invention, there is provided a
10 genset controller unit (GCU) for integrated handling of multiple gensets with
different operational requirements for power generation application. The GCU
comprise a plurality of communication units configured to communicate with a
plurality of genset components and a plurality of external devices using different
communication protocols. A memory device is configured to store information about
15 a plurality of operating parameters, a plurality of fault parameters and a plurality of
user setting parameters in accordance with each genset along with its operational
requirements. At least one master unit is communicatively coupled with an engine,
an alternator and an electronic control unit (ECU) of each genset through at least
one of the communication units for monitoring and controlling the operating
20 parameters of the engine and the alternator of each genset. One or more auxiliary
units are configured to monitor and control ON/OFF state of one or more
supplementary components of the gensets to maintain preset temperature and
supplementary constraint for operation of the gensets. At least one user interface is
connected with the master unit and the auxiliary units for acquiring and displaying
25 the operating, fault and user setting parameters and for selecting and activating
operating modes of each genset. The master unit and the auxiliary units are
interfaced with the gensets through the different communication protocols in such
a way that the master unit synchronizes the operational requirements of each of the
gensets by monitoring and regulating the operating parameters of each genset, and
30 determines auto mains failure (AMF) by continuously monitoring mains voltage
from a mains voltage terminal to automatically start the gensets if mains supply is
7
failed or cut off. Thus, the GCU is capable of achieving integrated handling of multiple
gensets with different operational requirements for power generation application in
an efficient, secure and cost effective manner.
5 [0016] According to first embodiment of present invention, the master unit
synchronizes different types and ratings of the gensets by determining at least the
operating parameters of voltage, frequency and phase angle of the gensets. After
synchronizing each of the gensets, the master unit operates each genset in a load
sharing mode for controlling genset load based on ratings of the gensets, and a load
10 demand mode for controlling genset load based on an external input into the GCU.
[0017] According to first embodiment of present invention, the master unit
constantly monitors and determines whether values of the operating parameters of
the engine and the alternator of each genset are within a range set for the specific
15 genset. If the master unit determines that the values of the operating parameters of
the genset are not within the set range of the genset, the GCU indicates and displays
an alert message to the user through the user interface or automatically stops the
operation of the genset. If the master unit detects any AMF and/or synchronisation
failures from the genset, the GCU indicates and displays an alert message to the user
20 through the user interface or automatically stops the operation of the genset.
[0018] According to first embodiment of present invention, the auxiliary units are
communicatively coupled with one or more coolant and oil heaters of the gensets
through different sensors to maintain preset temperature of coolant and oil in the
25 gensets and to provide ON/OFF command to the heaters.
[0019] According to first embodiment of present invention, the user interface is
designed as a human machine interface (HMI) touch screen display such that the
user communicates with the GCU to select and activate at least one of auto/manual
30 operating modes for starting or stopping the operation of the gensets. The HMI touch
8
screen display is configured to display warning messages, alarms and shutdown
messages of the gensets.
[0020] According to first embodiment of present invention, the master unit is
5 communicatively coupled to a circuit breaker of each of the gensets any one of the
communication protocols to automatically start or stop the operation of the gensets.
The master unit is communicatively coupled with an after treatment system
controller through one of the communication protocols for deciding and controlling
urea dosing in an exhaust system of the gensets.
10
[0021] According to first embodiment of present invention, the GCU is interfaced
with a remote monitoring system and a service tool through the communication
units via one of the communication protocols. The communication units comprise
CAN (Controller Area Network) ports, UART (Universal Asynchronous
15 Receiver/Transmitter) ports, serial ports, MODBUS ports, Ethernet ports, and Wi-Fi
module, and the communication protocols comprise CAN bus, UART communication,
serial communication, MODBUS, Ethernet, GSM (Global System for Mobile
Communications) communication.
20 [0022] According to first embodiment of present invention, the operating
parameters of the engine and the alternator of the gensets comprise engine voltage,
engine current, engine frequency, engine phase angle, engine speed, engine power
factor, engine lube oil pressure, engine coolant level, engine battery voltage, engine
coolant temperature, alternator voltage, alternator current, alternator frequency,
25 alternator phase angle, and alternator power factor.
[0023] According to second embodiment of present invention, there is provided a
method for integrated handling of multiple gensets with different operational
requirements for power generation application. The method comprises the steps of:
30 receiving and storing, by a memory device of a genset controller unit (GCU), a
plurality of operating parameters, a plurality of fault parameters and a plurality of
9
user setting parameters in accordance with each genset along with its operational
requirements through a plurality of communication units, wherein the plurality of
communication units is configured to communicate with a plurality of genset
components and a plurality of external devices using different communication
5 protocols. The operating parameters of an engine and an alternator of each genset
are monitored and controlled by a master unit of the GCU, wherein the master unit
is communicatively coupled with the engine, the alternator and an electronic control
unit (ECU) of each genset through at least one of the communication units. ON/OFF
state of one or more supplementary components of the gensets is monitored and
10 controlled by one or more auxiliary units of the GCU to maintain preset temperature
and supplementary constraint for operation of the gensets. The operating
parameters of each genset are regulated by the master unit to synchronize the
operational requirements of each of the gensets. Auto mains failure (AMF) is
determined by continuously monitoring mains voltage from a mains voltage
15 terminal by the master unit to automatically start the gensets if mains supply is
failed or cut off. The operating, fault and user setting parameters of the gensets, are
displayed on at least one user interface being connected with the master unit and
the auxiliary units of the GCU.
20 [0024] According to second embodiment of present invention, the master unit
synchronizes different types and ratings of the gensets by determining at least the
operating parameters of voltage, frequency and phase angle of the gensets. After
synchronizing each of the gensets, each genset is operated by the master unit in a
load sharing mode for controlling genset load based on ratings of the gensets, and a
25 load demand mode for controlling genset load based on an external input into the
GCU.
[0025] According to second embodiment of present invention, the master unit
constantly monitors and determines whether values of the operating parameters of
30 the engine and the alternator of each genset are within a range set for the specific
genset. If the values of the operating parameters of the genset are not within the set
10
range of the genset, an alert message is indicated and displayed to the user through
the user interface or the operation of the genset is automatically stopped. The
master unit detects any AMF and/or synchronisation failures from the genset, and if
the AMF and/or synchronisation failures are detected, indicating and displaying an
5 alert message to the user through the user interface or automatically stopping the
operation of the genset.
[0026] According to second embodiment of present invention, the auxiliary units
are communicatively coupled with one or more coolant and oil heaters of the gensets
10 through different sensors to maintain preset temperature of coolant and oil in the
gensets and to provide ON/OFF command to the heaters.
[0027] According to second embodiment of present invention, the user interface is
designed as a human machine interface (HMI) touch screen display such that the
15 user communicates with the GCU to select and activate at least one of auto/manual
operating modes for starting or stopping the operation of the gensets. The HMI touch
screen display is configured to display warning messages, alarms and shutdown
messages of the gensets.
20 [0028] According to second embodiment of present invention, the master unit is
communicatively coupled to a circuit breaker of each of the gensets any one of the
communication protocols to automatically start or stop the operation of the gensets.
The master unit is communicatively coupled with an after treatment system
controller through one of the communication protocols for deciding and controlling
25 urea dosing in an exhaust system of the gensets.
[0029] According to second embodiment of present invention, the GCU is interfaced
with a remote monitoring system and a service tool through the communication
units via one of the communication protocols. The communication units comprise
30 CAN (Controller Area Network) ports, UART (Universal Asynchronous
Receiver/Transmitter) ports, serial ports, MODBUS ports, Ethernet ports, and Wi-Fi
11
module, and the communication protocols comprise CAN bus, UART communication,
serial communication, MODBUS, Ethernet, GSM (Global System for Mobile
Communications) communication.
5 [0030] According to second embodiment of present invention, the operating
parameters of the engine and the alternator of the gensets comprise engine voltage,
engine current, engine frequency, engine phase angle, engine speed, engine power
factor, engine lube oil pressure, engine coolant level, engine battery voltage, engine
coolant temperature, alternator voltage, alternator current, alternator frequency,
10 alternator phase angle, and alternator power factor.
[0031] Other aspects, advantages, and salient features of the invention will become
apparent to those skilled in the art from the following detailed description, which,
taken in conjunction with the annexed drawings, discloses exemplary embodiments
15 of the invention.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0032] The above and other aspects, features and advantages of the embodiments
20 of the present disclosure will be more apparent in the following description taken in
conjunction with the accompanying drawings, in which:
[0033] FIG. 1 illustrates a general diagram of a genset controller unit (GCU) being
integrated with multiple gensets, in accordance with one exemplary embodiment of
25 the present invention.
[0034] FIG. 2 illustrates an overall system architecture of an integrated genset
controller unit (GCU) interfaced with different types and topology of genset
components, in accordance with one exemplary embodiment of the present
30 invention.
12
[0035] FIG. 3 illustrates a high level system architecture of an integrated genset
controller unit (GCU), in accordance with one exemplary embodiment of the present
invention.
5 [0036] FIG. 4 illustrates a block diagram of an integrated genset controller unit
(GCU), in accordance with one exemplary embodiment of the present invention.
[0037] FIG. 5 illustrates a system architecture depicting integration of a genset
controller unit (GCU) with an after-treatment system (ATS), in accordance with one
10 exemplary embodiment of the present invention.
[0038] FIG. 6 illustrates a flowchart of a method for integrated handling of multiple
gensets with different operational requirements for power generation application,
in accordance with another exemplary embodiment of the present invention.
15
[0039] Persons skilled in the art will appreciate that elements in the figures are
illustrated for simplicity and clarity and may have not been drawn to scale. For
example, the dimensions of some of the elements in the figure may be exaggerated
relative to other elements to help to improve understanding of various exemplary
20 embodiments of the present disclosure. Throughout the drawings, it should be noted
that like reference numbers are used to depict the same or similar elements,
features, and structures.
DETAILED DESCRIPTION OF THE INVENTION
25
[0040] The following description with reference to the accompanying drawings is
provided to assist in a comprehensive understanding of exemplary implementations
of the invention. It includes various specific details to assist in that understanding
but these are to be regarded as merely exemplary.
30
13
[0041] Features that are described and/or illustrated with respect to one
implementation may be used in the same way or in a similar way in one or more
other implementations and/or in combination with or instead of the features of the
other implementations.
5
[0042] According to FIG. 1, a general diagram of a genset controller unit (GCU)
(100) being integrated with multiple gensets (200) is illustrated in accordance with
one exemplary embodiment of the present invention. The present invention
describes a genset controller unit (GCU) (100) for integrated handling of multiple
10 gensets (“generator set”) (200) with different operational requirements for power
generation application, which is compatible to control variety of gensets of different
power ratings, types and topology. This integrated GCU (100) is facilitated with ease
of all combined genset features such as auto mains failure (AMF), synchronization,
variable power demands (Optiprime functionality), compatibility with different
15 ECUs, and interactive HMI (Human-Machine Interface) display with interactive UI
(User Interface) features. The GCU (100) provides a cost effective solution in
controlling multiple gensets (200) with different power ratings and different
operational topology.
20 [0043] For example, multiple gensets (200) are connected in parallel where some
of the gensets are active while others are in standby mode. Also, for example, a
network or chain of gensets may generate power together by sharing a load (e.g., by
different combinations of the gensets operating together and/or different gensets
operating under different operational parameters based on the power output
25 demands). For instance, during continuous operation of the system, the gensets
(200), when in parallel operation, may share the load with multiple other gensets in
the system. Due to differences in the underlying technology associated with power
generation in different types as well as differences in the hardware components and
operational topology/configurations of these gensets, the integrated GCU (100) of
30 the present invention is compatible and capable of synchronized controlling
different types of these gensets in an integrated and effective manner. It can result
14
in improve efficiency and performance of these gensets for power generation
application.
[0044] The system may include multiple gensets (200) with different types and
5 different power ratings used for the power generation application. The genset (200)
usually comprises an engine (202) and an alternator (204). The engine (202) can
include any type of engine that generates mechanical energy from by consuming a
fuel, such as a combustion engine (e.g., diesel engine, gas engine, or other engine that
uses a combination of gaseous and liquid fuels) or any other type of engine. In this
10 disclosure, it can be referred as Diesel Genset (DG) in some instances, which is
clearly for the purpose of exemplary explanation only, but not by the way of any
limitations or restrictions. The mechanical energy from the engine is then
transformed into electrical energy by the alternator (204) that is outputted by the
alternator as AC power.
15
[0045] According to FIG. 2, an overall system architecture of the integrated genset
controller unit (GCU) (100) interfaced with different types and topology of genset
components, is illustrated in accordance with one exemplary embodiment of the
present invention. The GCU (100) is designed as an integrated, modular and
20 customized controller unit to be in communication with different types of gensets
(200) for handling and controlling the operation of multiple gensets in an efficient
and synchronized manner. For example, the GCU (100) can be implemented using
any combination of hardware components, software components, digital circuitry,
and/or analog circuitry wired and/or otherwise configured to perform the functions
25 of the GCU described in the present disclosure. The GCU (100) is integrated with
multiple embedded electronics and control architecture related to different types of
the gensets (200), which can act as an universal electronic control system for any
types of the gensets (200).
30 [0046] The genset controller unit (GCU) (100) is a primary and supervisory control
unit for each genset, and handles different functions of the gensets (200). The GCU
15
(100) is integrated with major basic functions of the gensets (200) such as
monitoring of genset parameters, controlling genset functions and protection of the
gensets. The GCU (100) is interfaced with the engine or mechanical engine system
(202) of the gensets (200) using sensors or actuators and with the alternator (204)
5 of the gensets (200), which facilitates monitoring, controlling and protection of the
engine (202) and the alternator (204) of the gensets (200).
[0047] The GCU (100) is integrated with additional functions of the gensets (200),
i.e. is suitable and capable to handle remote monitoring, genset calibration/service
10 tools and customer BMS (Building Management System) systems in respect of the
gensets (200) from multiple manufacturers. The GCU (100) is integrated with userspecific or customized functions of the gensets (200), i.e. is suitable and capable to
handle electronic governor, voltage regulations, auto mains failure (AMF) function,
synchronization functions, load management and load sharing in accordance with
15 multiple gensets.
[0048] The GCU (100) is interfaced with an external system architecture of the
gensets (200), which is interfaced with ECU (Electronic Control Unit) (206),
mechanical engine system (202), alternator (204), external customer interface
20 (210) with configurable I/O (input/output), BMS (214), calibration/service tool
(208), external server interface (216) and distribution panel (212) of a genset
system.
[0049] The GCU (100) comprises at least three CAN ports for communicating with
25 the ECU (206), other GCU for LDSS (Load Dependent Start/Stop) and
calibration/service tool (208) for facilitating monitoring, controlling and
calibration/diagnostic of the ECU (206), other GCU and calibration/service tool
(208).
30 [0050] The GCU (100) comprises at least three UART for Modbus commination
with the HMI user interface and BMS system (214)for data communication. The GCU
16
(100) is also composed of an in-build capability or onboard remote monitoring unit
to transmit and communicate with a remote monitoring system (RMS) over
GSM/CDMM communication with the help of a server interface (216), and a serial
communication for USB (Universal Serial Bus) connection for data transmission. The
5 GCU (100) is also interfaced with a distribution panel (212) of the genset system for
controlling and feedback operations, and interfaced with the external user
connections (210) for monitoring, controlling and feedback operations.
[0051] The present genset controller unit (GCU) (100) is designed with modular
10 combination and configuration to achieve all genset functionalities without
compromising data sampling and critical operations of the gensets (200). The GCU
(100) provides more flexibility and modularity to cater all kind of genset user, i.e.
achieving genset control and monitoring, auto mains failure (AMF) functionality,
genset protection and additional input and outputs for customization.
15
[0052] According to FIG. 3, a high level system architecture of the integrated genset
controller unit (GCU) (100) is illustrated in accordance with one exemplary
embodiment of the present invention. The integrated genset controller unit (GCU)
(100) is categorized with different sections based on its operation. The system
20 structure of GCU (100) is designed with different sections or blocks, i.e. hardware &
base layer section (302), genset control state section (304), communication section
(314), configuration and I/O (Input/Output) block (306g), AMF and sync
functionality block (306f), alternator monitor and control section (306e), engine
monitor and control section (306d), alternator protection section (306a), engine
25 protection section (306b), AMF or sync protection section (306c), event handler
block (308), HMI section (310), and HMI and customer (user) interface (312).
[0053] The hardware & base layer section (302) is a main hardware circuit board
of the GCU (100). It comprises all the hardware components, which are driving the
30 peripheral subsystems of the GCU (100). This section (302) is arranged with several
components like main microcontroller, DC (Direct Current) power circuit, ADCs
17
(Analog-to-Digital Converter), on-board memory, physical layers of all network
communication protocols and peripheral active/passive electronic components.
This section (302) also comprises base software codes, where the board
initialization occurs.
5
[0054] The genset control state section (304) controls a main state flow of the GCU
(100), i.e. controlling the flow from starting till the running state. The genset control
state section (304) is also linked to a fault handling section and an event logging
section. The peripheral systems send input to the GCU (100), which drives this
10 control state section (304), and subsequently drives the outputs to run the genset
system.
[0055] The communication section (314) enables the GCU (100) to communicate
with sensors and peripheral sub systems of the gensets (200) over various
15 communication protocols, like CANBUS, UART, CAN, Serial or SPI (Serial Peripheral
Interface), MODBUS and Ethernet, which are managed and controlled by this
communication section (314). This communication section (314) is also responsible
for sending data to the remote monitoring device and service tool over various
communication protocols like GSM/CDMM communication.
20
[0056] The configuration and I/O block (306g) defines inputs and outputs of the
GCU (100), where there are 2 types of I/Os (analog and digital), which are divided
into fixed and configurable input/outputs. This configuration and I/O block (306g)
initializes all the I/Os, and latches the configurable I/Os to its dedicated general
25 purpose input/outputs from the microcontroller in the hardware & base layer
section (302) of the GCU (100).
[0057] The AMF (Auto Mains Failure) and sync functionality block (306f) is an addon functionality or feature in the GCU (100). This AMF and sync functionality block
30 (306f) can automatically start the genset (200) once mains power supply has been
cut off. The AMF and sync functionality block (306f) helps in synchronizing two or
18
more gensets (200) when the need arises, by matching primary parameters like
voltage, frequency and phase angle of the gensets (200). Also, these AMF and sync
functions can be incorporated into the system on user and system requirements.
5 [0058] The alternator monitor and control section (306e) monitors and controls
the alternator related parameters like line voltage, current, frequency, phase angle
and power of the alternator (204) of the gensets (200).
[0059] The engine monitor and control section (306d) monitors and controls
10 engine related parameters like engine speed, lube oil pressure, coolant level, battery
voltage and coolant temperature of the engine or engine system (202) of the gensets
(200).
[0060] The alternator protection section (306a) monitors the alternator
15 parameters and determines whether values of the alternator parameters are within
the set range or not. If the values of the alternator parameters are not within the set
range, i.e. goes above or below the set range, the GCU (100) indicates and displays a
warning message or shutdowns the genset system based on the severity of fault in
the values of the alternator parameters.
20
[0061] The engine protection section (306b) monitors the engine parameters and
determines whether values of the engine parameters are within the set range or not.
If the values of the engine parameters are not within the set range, i.e. goes above or
below the set range, the GCU (100) indicates and displays a warning message or
25 shutdowns the genset system based on the severity of fault in the values of the
engine parameters.
[0062] The AMF or sync protection section (306c) monitors the AMF and
synchronization parameters and determines whether values of the AMF and
30 synchronization parameters are within the set range or not. If the values of the AMF
and synchronization parameters are not within the set range, i.e. goes above or
19
below the set range, the GCU (100) indicates and displays a warning message or
shutdowns the genset system based on the severity of fault in the values of the AMF
and synchronization parameters.
5 [0063] The event handler block (308) manages any faults that occur in the genset
system. The faults can be categorized as active and inactive, and warning or
shutdown fault. The event handler block (308) is configured to maintain the history
of faults in the GCU (100).
10 [0064] The human machine interface (HMI) section (310) is designed of a touch
screen display with different dimensions (as per the user requirements) for enabling
the user to interactwith the GCU(100) and the genset system. The HMI section (310)
can communicate with the GCU (100) and its components over UART
communication and with the help of HMI and customer (user) interface (312). The
15 HMI section (310) is configured to perform primary operations and functions like
selecting operating modes (auto mode and manual mode) as well as starting and
stopping of the genset in manual mode.
[0065] According to FIG. 4, a block diagram of the integrated genset controller unit
20 (GCU) (100) is illustrated in accordance with one exemplary embodiment of the
present invention. The integrated genset controller unit (GCU) (100) primarily
comprises a master unit (402), one or more auxiliary units (404), an user interface
(406), a plurality of communication units (408) and a memory device (410). The
master unit (402) can also be referred as master card or base card or master
25 circuitry board, and similarly, the auxiliary units (404) can also be referred as
auxiliary cards or auxiliary circuitry boards. The user interface (406) is designed as
Human Machine Interface (HMI) display with different sizes like 5 Inch display, 7
Inch display and 10 Inch display. With the combination of these components, the
GCU(100) provides cost effective solutions to achieve all the flexibility requirements
30 of the genset user and the genset market.
20
[0066] The communication units (408) are communicatively connected to the
master unit (402) and the auxiliary units (404) in such a way that the
communication units (408) can facilitate the master unit (402) and the auxiliary
units (404) to communicate and understand any genset functions and parameters
5 irrespective of its types. The communication units (408) are configured to
communicate with a plurality of genset components and a plurality of external
devices and peripheral systems using various different communication protocols,
which enables the GCU (100) to communicate with any network topology. The
different communication protocols include, but not limited to, CAN (Controller Area
10 Network) bus for communication with the ECU, UART (Universal Asynchronous
Receiver/Transmitter) for communicating with the HMI user interface (406), GSM
(Global System for Mobile Communications) Wi-Fi module for wireless
communication, as well as MODBUS for communicating with a remote monitoring
system. The communication units (408) also include sensors and actuators to enable
15 communication between the GCU (100) and the mechanical engine system (202) of
the gensets (200).
[0067] The memory device (410) is arranged in the GCU (100) to store information
about several operating parameters, several fault parameters and several user
20 setting parameters in accordance with various types of gensets (200) in the genset
market. The memory device (410) is communicatively coupled with the master unit
(402) and the auxiliary units (404), where the memory device (410) includes, but
not limited to a random-access memory (RAM), a read-only memory (ROM) and a
flash memory.
25
[0068] The master unit (402) in the GCU (100) is configured to handle different
ratings and different operational topology of the gensets (200). The master unit
(402) is communicatively coupled with the engine or engine system (202) and the
alternator (204) of the gensets (200) through any one of the communication units
30 (408) for monitoring and controlling the operating parameters of the engine (202)
and the alternator (204) of the gensets (200). The auxiliary units (404) are
21
communicatively coupled with one or more coolant heaters, one or more oil heaters
and one or more supplementary components of the gensets (200) for monitoring
and controlling ON/OFF state of the coolant heaters, the oil heaters and the
supplementary components of the gensets (200) to maintain preset temperature of
5 coolant, oil and supplementary constraint of the gensets (200). The HMI user
interface (406) is connected with the master unit (402) and the auxiliary units (404)
to enable user to select and activate operating modes (i.e. auto and manual modes)
of the gensets (200).
10 [0069] The master unit (402) and the auxiliary units (404) are interfaced with the
gensets (200) through the different communication protocols in such a way that the
master unit(402) synchronizes operation of each of the gensets (200) by monitoring
and regulating the operating parameters of each of the gensets (200), and
determines auto mains failure (AMF) to automatically start the gensets (200) even
15 if mains supply is failed or cut off. The master unit (402) synchronises different types
of the gensets (200) by matching the operating parameters of voltage, frequency and
phase angle of the gensets (200).
[0070] The master unit (402) is configured to constantly monitor and determine
20 whether the operating parameters of the engine (202) and the alternator (204) of
the genset (200) are within a range set for the genset. If the master unit (402)
determines that the operating parameters of the genset (200) are not within the set
range of the genset, the GCU (100) indicates an alert message to the user or
automatically stops the operation of the genset (200).If the auto mains failure (AMF)
25 and/or the synchronisation failures are detected by the master unit (402), the GCU
(100) indicates an alert message to the user or automatically stops the operation of
the genset (200). The master unit (402) is communicatively coupled to a circuit
breaker of the gensets (200) to automatically stop the operation of the gensets
(200). The master unit (402) of one GCU (100) is also interfaced with other GCU
30 (100) by means of genset load-dependent start and stop (LDSS) parameters. The
22
master unit (402) is also integrated with an after treatment system (500) in the
engine or engine system (202) of the gensets (200).
[0071] The master unit (402) is the heart of the genset controller unit(GCU) (100),
5 and handles basic major functions of the genset controller unit (GCU). The basic
major functions of the GCU (100) comprises engine control, alternator control,
genset operation, auto mains failure, synchronization of two or more gensets, circuit
breaker control, integration with after treatment system, communication,
customized inputs and outputs, protection system, alarm and shutdown, and genset
10 load-dependent start and stop (LDSS). The master unit (402) is configured with the
requirements of all the basic major functions, and is capable to provide faster
analysis and response, protection algorithms, easy connectivity with customer
system, and easy modularity for better feature offering.
15 Engine Control Function
[0072] The engine control function is an important and critical function of the
master unit (402) in the GCU (100), where the GCU (100) plays a supervisory role
for controlling the engine (202) of the genset (200). The master unit (402) of the
GCU(100)is configured to manage a governing part of the engine (202) of the genset
20 (200). In the governing part of the engine (202), the master unit (402) of the GCU
(100) controls the power output of the engine (202) by maintaining set RPM
(Revolutions Per Minute) in a steady state condition and a transient condition. The
master unit (402) of the GCU (100) is configured and integrated with different
governing engine systems such as electronic system of ECU, electromechanical
25 governing system, mechanical governing system and cold starting kit, being used by
different types of gensets (200).
[0073] The master unit (402) is integrated with the ECU (206) in such a way that
the GCU (100) is communicated with the ECU (206) through a common
30 communication CAN bus protocol of J1939, where with this CAN bus protocol of
J1939, the master unit (402) of the GCU (100) can control the engine (202) of the
23
genset (200). The master unit (402) is integrated with the electromechanical
governing system in such a way that the GCU (100) is communicated with the
electromechanical governing system through different sensors, where an electronic
governor is a part of the complicated electromechanical governing system. The
5 master unit (402) enables the GCU (100) to receive feedback from the different
sensors and to communicate command signals to the electronic governor for
controlling speed of the engine (202) and managing load of the engine (202).
[0074] The master unit (402) is integrated with the mechanical governor in such a
10 way that the GCU (100) is communicated with the mechanical governor through
different sensors, which enables the GCU (100) to measure speed and different
parameters of the engine (202). The master unit (402) can read all engine
parameters, read all engine warnings, alarms and shutdowns as well as maintain
engine set speed of the engine (202). The master unit (402) in the GCU (100) is
15 arranged and configured to read different parameters of the engine (202) using
different principles based on the configuration of the engine of the different types of
gensets (200).
[0075] The master unit (402) is configured to read and control various engine
20 parameters, i.e. operating parameters of the engine (202) of the gensets (200). The
primary operating parameters of the engine (202) includes, but are not limited to
engine RPM (Revolutions Per Minute), coolant temperature, lube oil pressure, lube
oil temperature, intake manifold temperature, exhaust temperature for each
cylinder, battery voltage, engine running hours, fuel consumption, and lube oil
25 consumption.
[0076] For example, if the engine (202) is CRDI (Common Rail Direct Injection)
associated with the ECU (206), the master unit (402) of the GCU (100) can read all
parameters on the J1939 communication protocol, where this type of engine
30 configuration and parameters is available always to the master unit (402) of the GCU
(100). For example, if the engine (202) is associated with the electronic governing
24
system, the master unit (402) of the GCU (100) determines the communication
protocol available in the electronic governing system to communicate and read
partial or available parameters of the engine (202) from the electronic governor for
controlling and managing the engine (202) of the genset (200). This type of engine
5 configuration and parameters is available to the master unit (402) of the GCU (100).
For example, if the engine (202) is a mechanical engine, the master unit (402) of the
GCU (100) is connected directly with one or more sensors to read and control
various parameters of the mechanical engine (202) of the gensets (200). Thus, the
master unit (402) in the GCU (100) can able to manage and control all the
10 configuration of the engine (202) to handle multiple types of gensets (200) with any
ratings.
[0077] The master unit (402) is also configured to read all warnings, alarm and
shutdown of the engine (202) in the genset (200) as like similar configuration of
15 reading all the operating parameters from the engine (202). In case of electronic
engines (202) in the genset(200), the master unit (402) can determine and evaluate
all parameters relating to warnings, alarm and shutdown of the engine (202) via the
communication protocol J1939. In case of electronic governor in the genset (200),
the master unit (402) can determine and evaluate some parameters relating to
20 warnings, alarm and shutdown of the engine (202) via the communication protocol
available in the electronic governor as well as determine and evaluate some
parameters relating to warnings, alarm and shutdown of the engine (202) through
the sensors directly connected to the GCU (100). In case of mechanical engine (202)
in the genset (200), the master unit (402) can determine and evaluate all the engine
25 parameters relating to warnings, alarm and shutdown of the engine (202) through
the sensors directly connected to the GCU (100). For the electronic governor and the
mechanical engine (202), the GCU (100) is capable to create set points for each
warning and shutdowns of the engine (202), where the GCU (100) can facilitate the
user to alter and reset these set points based on configuration and requirements of
30 the engines (202) in the gensets (200).
25
[0078] Further, the screen of the HMI user interface (406)in the GCU (100) displays
the warnings, alarm and shutdown of the engine (202), which enables the GCU (100)
to indicate the displaying warning, alarm and shutdown on screen, to the user. In
case of any warnings and alarms in the engine (202) of the genset (200), the GCU
5 (100) is configured to activate a common potential free contact based on inputs
received by the GCU (100) from any kind of signals. For example, the common
potential free contact can be NO (Normally Open) type that can be converted to NC
(Normally Closed) when the alarm or warning is active. Similarly, in case of any
shutdowns in the engine (202) of the genset (200), the GCU (100) is configured to
10 activate a common potential free contact based on inputs received by the GCU (100)
from any kind of signals. For example, the common potential free contact can be NO
(Normally Open) type that can be converted to NC (Normally Closed) when the
shutdown is active. The HMI user interface (406) in the GCU (100) is provided with
a reset button on its screen, which enables the GCU (100) to reset all alarm, warning
15 and shutdown. If alarm, warning and shutdown are active from input side, there is
no effect by the reset button, where all alarm, warning and shutdown input can get
in healthy condition to reset the alarm, warning or shutdown from the GCU (100).
[0079] The master unit (402) of the GCU (100) is capable to maintain the engine
20 speed by determining and controlling the engine parameters of the genset engine
(202). In the genset application, the engine speed is usually decided and fixed at the
time of manufacturing, and the engine speed parameter is essential to be maintained
at its rating for proper output delivery. The engine speed is linked with various
genset parameters like frequency (Hz), voltage and etc. Normally, two type of the
25 engine speed is used for the genset application, i.e. one at engine speed of 1500 RPM
and second at engine speed of 1800 RPM. It is also used at engine speed of 3000 RPM
on few applications as well.
[0080] During production, the base file of the engine RPM is selected so that the
30 master unit in the GCU (100) ensures the engine to run on the set speed of RPM as
set during production. In case of CRDI and electronic engines (202), the ECU (206)
26
controls the engine speed by adjusting a fuelling system of the genset. In order to
operate multiple gensets (200) in the synchronisation mode, the master unit (402)
of the GCU (100) provides a biasing command signal to the ECU (206) to maintain
the speed as per synchronisation requirement. In case of electronic governor
5 engines (202), the master unit (402) of the GCU (100) provides a biasing command
signal to the electronic governor to maintain the speed as per synchronisation
requirement.
[0081] In case of mechanical engines (202), the master unit (402) of the GCU (100)
10 monitors the speed of the engine (202), and with reference to the monitored engine
speed, the master unit (402) of the GCU (100) calculates and displays the frequency
of the genset on the HMI screen (406, 310). Some of the correlation of the engine
speed and the frequency are 1500 RPM = 50 Hz, so 30 RPM = 1 Hz; 1800 RPM = 60
Hz, so 30 RPM = 1 Hz; 3000 RPM = 50 Hz, so 60 RPM = 1 Hz; and 3000 RPM = 60 Hz,
15 so 50 RPM = 1 Hz. With reference to the correlation of the engine speed and the
frequency, the GCU (100) displays the frequency on the HMI screen (406, 310),
which can be considered for synchronisation of multiple gensets (200) in operation.
[0082] The auxiliary units (404) of the GCU (100) are integrated and associated
20 with a cold starting kit to supply and operate the genset engine (202) at sub-zero
and higher altitude conditions. The auxiliary units (404) of the GCU (100) are
configured to control and manage ON / OFF condition of coolant heaters, oil heaters
and any other components of the genset (200). In this configuration, the auxiliary
units (404) of the GCU (100) maintains a temperature set for the coolant, oil and
25 other system such that the auxiliary units (404) monitor the temperature through
different sensors and provide ON / OFF command signals to the heaters to maintain
the temperature.
Engine Protection Function
30 [0083] The master unit (402) of the GCU (100) is configured to provide engine
protection based on application type of the gensets (200). In FAE (Full Authority
27
Engine) mode, the master unit (402) of the GCU (100) communicates with the ECU
(206) over the communication protocol J1939 such that the GCU (100) can able to
retrieve all Fault Codes (FC) over the communication protocol J1939 for protecting
the engine (202) in the genset (200). The list of FC can be supported by the GCU
5 (100) as per communication protocol J1939 standard based on SPN (Suspect
Parameter Number) / FMI (Failure Mode Identifier) codes. Whereas, in electro
mechanical mode, the master unit (402) of the GCU (100) protects the genset engine
(202) based on engine performance input to the master unit (402) of the GCU (100)
by checking with threshold values set for the engine (202), which enables the GCU
10 (100) to take decision of warning or shutdown of the gensets (200) based on the
severity of the fault. The list of FC needs to be supported by the GCU (100) includes,
but not limited to low oil pressure (Warning/Signal), over speed, HCT (High Coolant
Temperature), LCT (Low Coolant Temperature), fail to start, fail to crank, low
battery, high battery, weak battery and charging failure.
15
Alternator Control Function
[0084] The alternator control function is another important and critical function of
the master unit (402) in the GCU (100). The master unit (402) of the GCU (100) is
configured and integrated with the alternator (204) to monitor and control the
20 alternator (204) of the genset (200) by measuring and monitoring all alternator
parameters, voltage regulation and cold starting kit. The GCU (100) is a major
monitoring and controlling unit for the alternator (204) of the genset (200) without
the need for any other controller or supervisory module.
25 [0085] The master unit (402) of the GCU (100) directly monitors and controls
various operating parameters of the alternator (204) of the genset (200) through its
specific inputs connections made in the master unit (402). The various operating
parameters of the alternator (204) of the genset (200) includes, but not limited to
Voltage (Phase to Phase), Average Voltage (Phase to Phase), Voltage (Phase to
30 Neutral), Average Voltage (Phase to Neutral), Current (Phase to Phase), Average
Current, Current (Phase to Neutral), Frequency, Power factor (Per phase), Average
28
Power factor, Active Power kW (Per Phase), Average Active Power kW, Apparent
Power kVA (Per Phase), Average Apparent Power kVA, Reactive Power kVAR (Per
Phase), Average Reactive Power kVAR, Units Generated kWH, Cumulative Units
generated kWH, Excitation Current and Excitation voltage. All the above alternator
5 parameter are more important for user interface point of view, where some
parameters can be calibrated and calculated from the other parameters.
Alternator Parameter - Voltage
[0086] The master unit (402) of the GCU (100) can directly receive inputs of voltage
10 parameter from the alternator (204), where there are four terminals used in the GCU
(100) for voltage inputs. The voltage terminals in the master unit (402) of the GCU
(100) are capable to take care of the maximum voltage up to 690 V AC (alternating
current), and also internal protection can be provided for surge voltages. The voltage
input is usually in Phase to Phase and Phase to neutral can be calculated from Phase
15 to phase voltage. The selectable voltage inputs of 110 V AC (Phase to Phase) Voltage,
63 V AC (Phase to Neutral) Voltage, 415 to 440 V AC (Phase to Phase) Voltage and
240 to 260 V AC (Phase to Neutral) Voltage, can be required in the GCU (100) for
voltage display.
20 [0087] In normal conditions, majorly 415 V AC is used but 110 V AC system is used
for the HV (High Voltage) system like 3.3 kV, 6.6. KV and 11 kV system. The 110 V AC
system can be selected for the 3.3 kV / 6.6 kV or 11 kV system, and all related
parameters can be aligned with this voltage inputs. It is required to have at least one
selection option in the GCU (100) to set-up page from which single phase or 3 phase
25 system can be selected. If single phase system is selected then only one phase and
neutral are connected at the terminal. For example, the genset voltage terminal
(GVT) in the GCU (100) is defined as below:
· 1 – R Phase
· 2 – Y Phase
30 · 3 – B Phase
· 4 – Neutral
29
In case of 3 phase system, all terminals are connected and for single phase only
terminal 1 and terminal 4 are connected.
Alternator Parameter - Current
5 [0088] The master unit (402) of the GCU (100) can directly receive inputs of
current parameter from the alternator (204) through its current transformer, where
there are six terminals used in the GCU (100) for current inputs. The current display
depends on the CT (current transformer) ratio. The terminals on the master unit
(402) of the GCU (100) are capable to take current up to 10 Amp and provided with
10 a protection fuse in it. Normally, the followings are input current for the master unit
(402) of the GCU (100) which is configured with the primary current of the CT.
· 1 Amp[SR1]
· 5 Amp
The above can be selectable settings in the GCU (100). During normal conditions, 5
15 Amp system is used for the LT (Low Tension) and 1 Amp system is used for the HT
(High Tension) system. For example, the genset current terminal (GCT) in the GCU
(100) is defined as below:
· 1 – S1 – R Phase
· 2 – S2 – R Phase
20 · 3 – S1 – Y Phase
· 4 – S2 – Y Phase
· 5 – S1 – B Phase
· 6 – S2 – B Phase
With the selection of the 1 Amp or 5 Amp, the input are provided in the setup for
25 rated current of the genset (200). The master unit (402) of the GCU (100) displays
the actual current on the display screen of HMI (406, 310) in the GCU (100). For
example, if the rated current set point is 1600 Amp and the master unit input is
selected to 5 Amp and CT ratio is 320. The displayed current can be varied with this
ratio and input current at the master unit (402). If the input current is 3 Amp, the
30 GCU (100) displays the current 3 X 320 = 960 Amp on the HMI screen (406, 310),
30
where the protection and display system for the genset also work with the same
inputs.
Alternator Parameter - Frequency
5 [0089] The master unit (402) of the GCU (100) is configured to calculate the
frequency parameter from the speed of the engine (202) in the genset (200), where
this frequency parameter is an important parameter linked with the operation of the
genset (200). This frequency parameter is set during the manufacturing, and is
provided in two options, i.e. 50 Hz and 60 Hz, where both of these parameters are
10 directly linked with the engine parameter. If the engine RPM is 1500 RPM, the
frequency parameter can be 50 Hz. Whereas, if the engine RPM is 1800 RPM, the
frequency parameter can be 60 Hz.
Alternator Parameter - Power Factor
15 [0090] The master unit (402) of the GCU (100) is configured to monitor the
power factor parameter by calculating cosine angle between current and voltage for
each phase, where this power factor parameter is another important parameter to
monitor and calculate the actual power usage of the genset (200). The power factor
parameter is essential to calculate different powers like actual power, apparent
20 power and reactive power in the operation of the genset (200). The power factor
parameter is displayed in three stages in the screen (406, 310) of the GCU (100),
which are:
• If the angle between voltage and current is zero, the power factor parameter
is unity, which is displayed as 1 on the HMI screen (406, 310) of the GCU
25 (100).
• If the angle between voltage and current is zero to 90 degrees, the power
factor parameter is legging, which is displayed with positive sign on the HMI
screen (406, 310) of the GCU (100).
• If the angle between voltage and current is 90 to 180 degrees, the power
30 factor parameter is leading, which is displayed with negative sign on the HMI
screen (406, 310) of the GCU (100).
31
The power factor parameter can be used to calculate actual power and apparent
power, i.e. if the power factor is more than 1, it can be shown as negative or leading
power factor, whereas if the power factor is less than 1, it can be shown as positive
or lagging power factor.
5
Alternator Parameter - Actual Power (kW)
[0091] The master unit (402) of the GCU (100) is configured to measure actual
power of the genset directly from the genset (200), which is displayed on the HMI
screen. This actual power parameter is also an important parameter for the
10 operation of the genset (200). The actual power parameter is continuously
monitored by the master unit (402) of the GCU (100) to perform various controlling
and adjustment of the operation of the genset system, i.e. the actual power
parameter can be used for protection system and different genset operations.
15 Alternator Parameter - Apparent Power (kVA)
[0092] The genset rating is declared in the apparent power output, and the
master unit (402) of the GCU (100) is configured to measure and display apparent
power parameter on the HMI screen. The parameters of apparent power and actual
power are used to calculate the power factor of the genset system.
20
Alternator Parameter - Reactive Power (kVAR)
[0093] The master unit (402) of the GCU (100) is configured to measure,
monitor and display reactive power parameter on the HMI screen, which is essential
for an electrical system of the genset.
25
Alternator Parameter - Unit Generated (kWH)
[0094] The master unit (402) of the GCU (100) is configured to continuously
monitor and calculate unit or energy generated by the genset (200), as per the
production of the genset, based on active power generated by genset (200). This
30 parameter is stored in the memory device (410) in the GCU (100) and is essential
for calculating efficiency and fuel consumption of the genset (200).
32
Alternator Parameter - Excitation Current
[0095] The master unit (402) of the GCU (100) is configured to monitor
excitation current parameter of the genset (200), which is essential and used for
5 controlling and monitoring the voltage or the voltage output of the alternator (204)
in the genset (200) since the excitation current parameter can change the output
voltage of the alternator (204). The monitoring and controlling of monitor excitation
current parameter is used in trouble shooting requirement to resolve issues or faults
in the alternator (204).
10
Alternator Parameter - Excitation Voltage
[0096] The master unit (402) of the GCU (100) is configured to monitor
excitation voltage parameter of the genset (200), which is essential and used for
controlling and monitoring the voltage or the voltage output of the alternator (204)
15 in the genset (200). Based on the AVR (Automatic Voltage Regulator) system, the
master unit (402) of the GCU (100) can able to control either excitation voltage or
excitation current for controlling the voltage or the voltage output of the alternator
(204) in the genset (200). The master unit (402) of the GCU (100) facilitates the
monitoring and controlling of different parameters of the alternator (204) in the
20 genset (200).
Alternator Protection Function
[0097] The master unit (402) of the GCU (100) is capable to protect the
alternator (204) from any scenario or faults by controlling the parameters of the
25 alternator (204), and also displays the fault as an alarm or warning in the HMI screen
(406, 310) of the GCU (100). The essential fault protections provided by the GCU
(100) includes, but are not limited to High AC voltage, Low AC voltage, Loss of AC
voltage sensing, Over Frequency, Under Frequency, Over Current (Signal/Warning),
Current Unbalancing, Over Load (kW based) and Over Excitation.
30
33
Event Handler
[0098] The GCU (100) is arranged with the separate memory device (410) for
storing information about various operating parameters as well as various fault
5 parameters in accordance with the genset (200), where the fault parameters
comprise active faults and inactive faults. The GCU (100) also indicates the
information about these faults on the HMI screen (406, 310).
[0099] Active Fault: When there is any active fault in the GCU (100), the GCU
10 (100) stores it in the location based on warning or shutdown. In active shutdown,
the GCU (100) stores the current active shutdown faults, where the faults need to
work as FIFO (First In, First Out) manners based on a time stamp. The GCU (100) is
capable to store at least 5 numbers of shutdown fault parameters or information in
the memory device (410). The fault line information typically includes a fault
15 description (using SNP (Suspect Parameter Number)/FMI (Failure Mode
Identifier)), SA (System Action) and engine hour (Hr) information, which are used
to pinpoint the cause and nature of a fault. Similarly, in active warning, the GCU (100)
stores the current active warning faults, where the faults need to work as FIFO
manners based on the time stamp. The GCU (100) is capable to store at least 5
20 numbers of warning fault parameters or information in the memory device (410).
The fault line information typically includes a fault description (using SNP/FMI), SA
and engine Hr information, which are used to pinpoint the cause and nature of a
fault.
25 [00100] Inactive Fault: The GCU (100) stores the inactive faults based on the
occurrence and severity in the memory device (410) in FIFO manner. The GCU (100)
is capable to store at least 20 fault storing capacity. The fault line information
typically includes a fault description (using SNP/FMI), SA, engine Hr, fault severity
and occurrence information.
30
34
Genset Operation - Auto Mains Failure (AMF)
[00101] With the current market requirement, all gensets (200) have to meet
Auto Mains Failure operational requirement. The GCU (100) is capable to handle the
critical operation of Auto Mains Failure (AMF) in the genset application. In this
5 operation, the master unit (402) of the GCU (100) receives inputs of mains voltage
R.Y, B and N through MVT (Mains Voltage Terminal), and determines AMF by
continuously monitoring the mains voltage through the MVT such that the GCU
(100) can initiate start / stop command signals to the genset (200) with respect to
status of the mains voltage of the genset (200), which enables automatic start of the
10 genset (200) even if the mains supply is failed or cut off, by triggering motors of the
engine (202) of the genset (200) and closing the circuit breaker of the genset (200).
The Mains Voltage Terminal (MTV) is defined as:
· 1 – R Phase
· 2 – Y Phase
15 · 3 – B Phase
· 4 – Neutral
The GCU (100) issues a start command signal to the engine starting motor based on
the conditions that if all 3 phases get failed from mains and/or if one of phase gets
failed (single phasing condition) from mains.
20
[00102] With reference to the above condition and inputs, the master unit (402)
of the GCU (100) initiates the start command signal to the starting motors of the
engine (202) and simultaneously initiates open command to a fuel valve (in case of
diesel engine). Accordingly, the genset (200) is operated at the rated RPM and
25 voltage, and the GCU (100) manages the set RPM and voltage of the genset (200) if
it is in biasing mode. Then, the GCU (100) (i.e. the master unit (402) of the GCU) is
integrated with the circuit breaker of the genset (200) to trigger a close command
signal to the genset breaker to feed power to available load connected to the genset
(200).
30
35
[00103] The GCU (100) ensures the continuous operation of the genset (200) to
feed the power to load until the mains supply gets restored. As soon as the mains
supply gets restored, the GCU (100) senses the mains voltage by its continuous
monitoring through the MVT, and the GCU (100) first initiates open command
5 signals to the circuit breaker of the genset (200) after expiry of a preset waiting
period (for example, waiting for 2 minutes with editable setting). Then, the GCU
(100) allows the genset (200) to operate for an extended period of preset minutes
(for example, a period of 10 minutes with editable setting), and the GCU (100)
initiates close command signal to the fuel valve for stopping the operation of the
10 genset (200) after expiry of the preset extended period.
Genset Operation - Engine / Genset starting process
[00104] The master unit (402) of the GCU (100) is capable to handle the critical
operation for starting the genset(200). For starting the genset(200), the master unit
15 (402) of the GCU (100) sends a start command signal to start the motor of the genset
(200) and simultaneously sends an open command signal to the fuel valve when the
utility of mains or grid power supply cuts off. Both the start command and open
command signals remain unchanged until the genset engine (202) reaches the
operational speed of 180 RPM (set point is editable) or 1 minutes (set point is
20 editable) whichever is earlier, and thereafter, the master unit (402) of the GCU (100)
removes the start command signal of the starting motor and retains the open
command to the fuel valve.
[00105] If the genset engine (202) does not reach 180 RPM within 1 minute time,
25 the GCU (100) removes both the start and open command signals to the motor and
the fuel valve. Thereafter, the GCU (100) waits for 1 Minutes (set point is editable)
and initiates a second start command signal to the genset motor. The GCU (100)
follows similar steps for the second start command as like the first start command
signal. If the genset engine still does not start with the second start command, the
30 GCU (100) waits for 1 Minutes and initiates a third start command signal to the
genset motor. The GCU (100) follows similar steps for the third start command as
36
like the first start command signal. If the genset engine (202) does not start even at
the third start command signal, the GCU (100) initiates and sends an alarm that the
engine (202) is not starting, and also operates the common alarm contact. After the
third start command signal, no further start command signal is initiated by the GCU
5 (100) to start the motor and the fuel valve, and simultaneously the GCU (100) sends
a close command signal to the fuel valve of the genset engine (202). In Auto Mains
failure (AMF) condition, the genset (200) runs in an isolation mode and runs with
all the load available in the genset system.
10 Genset Operation – Synchronization
[00106] The master unit (402) of the GCU (100) is capable to handle another
critical function of synchronization of the genset operation in the genset system,
which is more essential on the genset (200) with different types, sources and loads.
For synchronization of the genset operation, the master unit (402) of the GCU (100)
15 monitors and determines at least the parameters of voltage level, frequency and
phase angle, before operating or closing the circuit breaker of the genset (200). The
master unit (402) of the GCU (100) ensures timing for operating or closing the
circuit breaker of the genset (200) when all the parameters of voltage level,
frequency and phase angle are matched with different types of gensets (200),
20 different sources and different loads, i.e. synchronization of multiple gensets and
synchronization of gensets to mains.
[00107] To ensure better system integration for synchronization, the master unit
(402) of the GCU (100) retrieves at least the following inputs from the different
25 sources, i.e.
• Voltage input of genset
• Voltage input from another source (genset or main grid)
• Breaker control of synchronization breaker
• Communication lines between multiple gensets (for faster response between
30 multiple gensets)
37
In both the synchronization of multiple gensets and the synchronization of gensets
to mains, the master unit (402) of the GCU (100) checks any variation or change in
the parameters of voltage level, frequency and phase angle, before operating or
closing the circuit breaker of the gensets (200). In the synchronization of gensets to
5 mains, the master unit (402) of the GCU (100) checks any variation or change in the
parameters of voltage and frequency level of the mains during the synchronization
activity. Whereas, in the synchronization of multiple gensets, the master unit (402)
of the GCU (100) checks any variation or change in the parameters of voltage and
frequency level of each genset (200) through communication lines being connected
10 with multiple gensets (200) to communicate between multiple gensets, where the
communication lines maintain the voltage and frequency for faster response.
[00108] For example, if two or more gensets (200) receive the start command
signal at same time, the master unit (402) of the GCU (100) activates the
15 communication lines between multiple gensets (200) to decide at least one master
genset from multiple gensets based on the genset that first reaches the set RPM and
voltage. Once the first master genset (200) achieves the set RPM and voltage, the
mater unit (402) of the GCU (100) actuates to close the first genset breaker in a dead
bus mode, and holds the closing of the genset breaker for a moment that all other
20 gensets (200) achieves the set RPM and voltage, i.e. all the gensets (200) are entered
into a synchronization mode, and the master unit (402) of the GCU (100) actuates to
close all the genset breaker as soon as synchronization conditions are met.
[00109] During the synchronization, the genset (200) is operated in two different
25 operation modes, i.e. load sharing mode and load demand mode. Normally after the
synchronization, the gensets (200) are operated in the load sharing mode. In this
load sharing mode, the gensets (200) share the available load as per the genset
ratings, where it is applicable for both kind operations, i.e. synch with grid and synch
with multiple gensets (200). In the load sharing mode, it is important that the
30 gensets (200) share both power like active and reactive power for balancing
operation. In order to maintain the power balancing, the GCU (100) maintains the
38
voltage within minimum tolerance using P, I & D (Proportional-Integral-Derivative)
algorithm to match the voltage of the genset(200), which helps to balance power on
all connected gensets (200).
5 [00110] For example, if the genset (200) is synch with the grid, there is no much
control of load managed by the GCU (100) and the GCU (100) has to ensure power
availability for the load based on the available load on the genset (200). If multiple
gensets (200) with similar ratings are operating in the synchronization mode, the
master unit (402) of the GCU (100) monitors and controls load balancing to equally
10 share the load on each of the gensets (200). In case that both the gensets are 100
kVA, and available load is 150 kVA, then the GCU (100) controls both the gensets to
run on 75 kVA. If the load is 80 kVA, then the GCU (100) controls both the gensets to
run on 40 kVA.
15 [00111] Similarly, if multiple gensets (200) with different ratings are operating in
the synchronization mode, the master unit (402) of the GCU (100) monitors and
controls load balancing based on percentage of the ratings of each of the gensets
(200).
20 [00112] In case that if one genset is 100 kVA, another genset is 200 kVA and
available load is 250 kVA, then the GCU (100) controls the 100 kVA genset to run on
83 kVA and controls the 200 kVA genset to run on 166 kVA by sharing and balancing
the load with 83% on the ratings of each genset. Thus, the master unit (402) of the
GCU (100) facilitates equal percentage of loading on each of the gensets (200) based
25 on its power ratings, which protects the genset (200) with low ratings against
overloading by keeping mere equal loading on the gensets (200) without
differentiating with its ratings.
Load sharing operation:
30 [00113] The master unit (402) of the GCU (100) initiates the start command to
both gensets (200) once the mains failure input is received, such that the GCU (100)
39
operates the gensets (200) to run at rated or set RPM and voltage by closing both
the genset breakers in dead bus or synchronization mode. Then, the load can be
shared on both the gensets (200) and the master unit (402) of the GCU (100)
monitors the load on each genset (200). The master unit (402) of the GCU (100)
5 requires set points of Stop in the ranges of 10% to 40% and Start in the range of 60%
to 90% for better fuel consumption and operational requirements. The GCU (100)
waits initial 10 minutes for the load on each genset (200). If the load on each genset
is less than stop set point in the GCU (100), the GCU (100) checks for running hours
of the genset (200) and initiates a stop command signal to the genset being operated
10 at higher running hours. In order to stop the genset, the GCU(100) gradually reduces
or lowers the load on the genset (200) at higher running hour as per the slop of load
reduction. The genset breaker can open at last 5% load on the genset. The genset
(200) runs for 5 minutes after opening the genset breaker, and then the genset
operation stops after expiry of 5 minutes. If the genset load reaches higher than the
15 start set point, the GCU (100) initiates the start command to the genset, and the
genset (200) starts and closes the genset breaker in the synchronization mode. The
GCU (100) increases the load on new genset till both loaded as per load sharing
values or parameters. If the GCU (100) receives a main restoration input, the GCU
(100) is configured to open the genset breaker and transfer the load on the mains
20 supply, and the genset (200) is stopped after running for 10 minutes.
Load Demand operation:
[00114] In a load demand mode of operation, the master unit (402) of the GCU
(100) is integrated with a load demand mode input to recognize work in a load
25 demand mode of operation, which is a simplest mode of operation. This load demand
mode operates with external input like 0 – 5 V DC or 4 – 20 mA input, i.e. 0 VDC or 4
mA can be considered as 0 kVA whereas 5VDC or 20 mA can be considered as highest
rating of the genset (200). In this load demand operation, the master unit (402) of
the GCU (100) monitors the external input and controls the genset (200) based on
30 the external input. It is not linked with the other genset or mains operation. In order
to enable this load demand mode of operation, it is required to have another genset
40
or mains parallel system. If other genset or mains gets failed, the GCU (100) removes
the load demand mode and operates the genset (200) in the load sharing mode.
[00115] The GCU (100) handles various operational functions described above
5 with the help of various network communications and protocols. The GCU (100) is
arranged with at least three CAN ports for communicating with ECU, Other GCU (for
LDSS) and Calibration/service tool. The GCU (100) is arranged with at least three
UART ports for Modbus communication with the HMI and BMS system. The GCU
(100) is arranged with an in-build capability of remote monitoring and transmits it
10 over GSM/CDMM communication. The GCU (100) is also arranged with a serial
communication for USB connection for other data transmission.
[00116] According to FIG. 5, a system architecture depicting integration of a
genset controller unit (GCU) (100) with an after-treatment system (ATS) (500), is
15 illustrated in accordance with one exemplary embodiment of the present invention.
The genset controller unit (GCU) (100) is integrated with an after-treatment system
(ATS) controller (500), i.e. the master unit (402) of the GCU (100) is
communicatively coupled with the ATS controller (500) for controlling aftertreatment system application in the engine (202) of the genset (200). The ATS
20 controller (500) receives control inputs from the master unit (402) of the GCU (100)
and receives inputs from various peripheral sensor based systems for controlling
output of urea dosing in an exhaust system of the genset (200). The ATS controller
(500) is communicatively coupled with the GCU (100) and various peripheral sensor
based systems with the help of different communication protocols to receive
25 multiple inputs via these different communication protocols.
[00117] The GCU (100) communicates with the ATS controller (500) via CAN bus
protocol. Similarly, the ATS controller (500) is connected to an urea quality and DEF
(Diesel Exhaust Fluid) level sensor and a Nox (Nitrogen Oxides) sensor via CAN bus
30 protocol. The ATS controller (500) receives CAN inputs from the GCU (100), the urea
quality and DEF level sensor and the Nox sensor. The after-treatment system
41
controller (500) is provided with an in-built ADC (Analog to Digital Converter) to
receive analog inputs such as ATS (Automatic Transfer Switch) inlet and outlet
pressure, ATS inlet and outlet temperature, temperature and manifold absolute
pressure, barometric pressure and delta P across DPF (Diesel Particulate Filter)
5 from various peripheral sensor based systems. The ATS controller (500) receives
and processes multiple inputs from the GCU (100) and the peripheral sensor based
systems to decide and control urea dosing in the exhaust system over high side
driving PWM (Pulse Width Modulation) output.
10 [00118] The present invention of integrated genset controller unit (GCU) (100) is
a standalone, reliable and intelligent genset controller capable of handling all GCU
features combined with additional features such as AMF function, synchronization
function, optiprime function, which is compatible with different types and power
ratings of multiple gensets (200), is compatible with different ECUs of multiple
15 gensets and facilitates interactive UI features through its interactive HMI display. The
GCU (100) is arranged with various general purpose input and output pins, which
can receive external parameters as input to respectively drive necessary outputs to
carry out all the GCU features combined with additional features such as AMF
function, synchronization function, optiprime function. The GCU (100) is capable of
20 handling both analog and digital inputs & outputs. The GCU (100) is capable of
communicating to various peripheral systems using different communication
protocols, like CANBUS for communication with the ECU, UART for communicating
with the HMI screen, GSM Wi-Fi module for wireless communication, as well as
MODBUS for communicating with the remote monitoring system. The GCU (100) is
25 also provided with an inbuilt fault detection and handling system. The GCU (100) is
also capable of handling start/stop functionality, which can be carried out in both
manual method and remote operation.
[00119] According to FIG. 6, a flowchart of a method for integrated handling of
30 multiple gensets (200) with different operational requirements for power
generation application, is illustrated in accordance with another exemplary
42
embodiment of the present invention. The method is implemented in the genset
controller unit (GCU) (100) for integrated handling of multiple gensets (200) with
different operational requirements for power generation application. The GCU (100)
comprises a master unit (402), one or more auxiliary units (404), HMI user interface
5 (406), communication units (408) and memory device (410), where the master unit
(402) is capable to perform engine control, alternator control, genset operation with
auto mains failure and synchronization of gensets, breaker control, integration with
after-treatment systems, communication through various protocols, and customized
inputs and outputs. The GCU (100) is capable of handling analog and digital inputs
10 and outputs, supporting communication protocols including CANBUS, UART, GSM,
and MODBUS, and providing start/stop functionality in both manual and remote
modes. The GCU (100) also provides inbuilt fault detection and handling to ensure
genset protection and efficient load management and sharing.
15 [00120] At step 602, the GCU (100) receives and stores, at its memory device
(410), various operating parameters, various fault parameters and various user
setting parameters in accordance with each genset (200) along with its operational
requirements with the help of different communication units (408). The different
communication units (408) are configured to communicate with several genset
20 components and several external devices using different communication protocols.
The communication units (408) comprise CAN (Controller Area Network) ports,
UART (Universal Asynchronous Receiver/Transmitter) ports, serial ports, MODBUS
ports, Ethernet ports, and Wi-Fi module, and the communication protocols comprise
CAN bus, UART communication, serial communication, MODBUS, Ethernet, GSM
25 (Global System for Mobile Communications) communication. The GCU (100) is also
interfaced with a remote monitoring system and a service tool through the
communication units (408) via one of the communication protocols.
[00121] At step 604, the operating parameters of an engine (202) and an
30 alternator (204) of each genset (200) are monitored and controlled by the master
unit (402) of the GCU (100). The master unit (402) is communicatively coupled with
43
the engine (202), the alternator (204) and an electronic control unit (ECU) (206) of
each genset (200) through at least one of the communication units (408). At step
606, ON/OFF state of one or more supplementary components of the gensets (200)
is monitored and controlled by the auxiliary units (404) of the GCU (100) to maintain
5 preset temperature and supplementary constraint for operation of the gensets
(100). The auxiliary units (404) are communicatively coupled with one or more
coolant and oil heaters of the gensets (200) through different sensors to maintain
preset temperature of coolant and oil in the gensets (200) and to provide ON/OFF
command to the heaters.
10
[00122] At step 608, the operating parameters of each genset (200) are regulated
by the master unit (402) to synchronize the operational requirements of each of the
gensets (200). The master unit (402) and the auxiliary units (404) are interfaced
with the gensets (200) through the different communication protocols to obtain
15 various information from the gensets (200) for monitoring and controlling the
gensets (200). The operating parameters of the engine (202) and the alternator
(204) of the gensets (200) comprise engine voltage, engine current, engine
frequency, engine phase angle, engine speed, engine power factor, engine lube oil
pressure, engine coolant level, engine battery voltage, engine coolant temperature,
20 alternator voltage, alternator current, alternator frequency, alternator phase angle,
and alternator power factor. The master unit (402) synchronizes different types and
ratings of the gensets (200) by determining at least the operating parameters of
voltage, frequency and phase angle of the gensets (200). After synchronizing each of
the gensets (200), each genset (200) is operated by the master unit (402) in a load
25 sharing mode for controlling genset load based on ratings of the gensets (200), and
a load demand mode for controlling genset load based on an external input into the
GCU (100).
[00123] At step 610, auto mains failure (AMF) is determined by continuously
30 monitoring mains voltage from a mains voltage terminal by the master unit (402) to
automatically start the gensets (200) if mains supply is failed or cut off. The master
44
unit (402) detects any AMF and/or synchronisation failures from the genset (200),
and if the AMF and/or synchronisation failures are detected, indicating and
displaying an alert message to the user through the user interface (406) or
automatically stopping the operation of the genset (200).
5
[00124] At step 612, the operating, fault and user setting parameters of the
gensets (200), are displayed on the user interface (406) being connected with the
master unit (402) and the auxiliary units (404) of the GCU (100). The user interface
(406) is designed as a human machine interface (HMI) touch screen display (406)
10 such that the user communicates with the GCU (100) to select and activate at least
one of auto/manual operating modes for starting or stopping the operation of the
gensets (200). The HMI touch screen display (406) is configured to display warning
messages, alarms and shutdown messages of the gensets (200). The user interface
(406) in the GCU (100) enables the user to select and activate operating modes of
15 each genset (200). The master unit (402) constantly monitors and determines
whether values of the operating parameters of the engine (202) and the alternator
(204) of each genset (200) are within a range set for the specific genset (200). If the
values of the operating parameters of the genset (200) are not within the set range
of the genset (200), an alert message is indicated and displayed to the user through
20 the user interface (406) or the operation of the genset (200) is automatically
stopped. The master unit (402) is communicatively coupled to a circuit breaker of
each of the gensets (200) any one of the communication protocols to automatically
start or stop the operation of the gensets (200). The master unit (402) is also
communicatively coupled with an after treatment system controller (500) through
25 one of the communication protocols for deciding and controlling urea dosing in an
exhaust system of the gensets (200).
[00125] The present invention is capable of achieving integrated handling of
multiple gensets with different operational requirements for power generation
30 application in an efficient, secure and cost effective manner, i.e. it achieves faster
analysis and provides cost effective solution to handle various gensets of different
45
ratings and operating features. It is flexible and compatible with any gensets of
different power ratings, sources, configurations and operational topology without
increasing overall costing in genset power applications. It facilitates easy
connectivity and easy modularity with any gensets for better features and offerings
5 to cover all requirements of customers and genset market.
[00126] Although the present disclosure has been described in accordance with
the embodiments, it is understood that the present disclosure is not limited to the
embodiments and structures described above. The present disclosure encompasses
10 various modification examples or variations within the scope of equivalents. Various
combinations or forms as well as other combinations or forms including only one
element, one or more elements, or one or less elements, fall within the scope of the
present disclosure.
15 [00127] Also, it will be appreciated by those skilled in the art that various changes
and modifications may be made to the embodiments described herein without
departing from the scope of the invention. It is intended that the invention not be
limited in any way by the embodiments shown and described herein, but that the
invention be limited only by the claims appended hereto.
20
46
WE CLAIM:
1. A genset controller unit (GCU) for integrated handling of multiple gensets
with different operational requirements for power generation application,
5 comprising:
a plurality of communication units configured to communicate with a
plurality of genset components and a plurality of external devices using different
communication protocols;
a memory device configured to store information about a plurality of
10 operating parameters, a plurality of fault parameters and a plurality of user setting
parameters in accordance with each genset along with its operational requirements;
at least one master unit communicatively coupled with an engine, an
alternator and an electronic control unit (ECU) of each genset through at least one
of the communication units for monitoring and controlling the operating parameters
15 of the engine and the alternator of each genset;
one or more auxiliary units configured to monitor and control ON/OFF state
of one or more supplementary components of the gensets to maintain preset
temperature and supplementary constraint for operation of the gensets; and
at least one user interface connected with the master unit and the auxiliary
20 units for acquiring and displaying the operating, fault and user setting parameters
and for selecting and activating operating modes of each genset,
wherein the master unit and the auxiliary units are interfaced with the
gensets through the different communication protocols in such a way that the
master unit synchronizes the operational requirements of each of the gensets by
25 monitoring and regulating the operating parameters of each genset, and determines
auto mains failure (AMF) by continuously monitoring mains voltage from a mains
voltage terminal to automatically start the gensets if mains supply is failed or cut off.
2. The GCU as claimed in claim 1, wherein the master unit synchronizes
30 different types and ratings of the gensets by determining at least the operating
parameters of voltage, frequency and phase angle of the gensets.
47
3. The GCU as claimed in claims 1 and 2, wherein after synchronizing each of
the gensets, the master unit operates each genset in a load sharing mode for
controlling genset load based on ratings of the gensets, and a load demand mode for
controlling genset load based on an external input into the GCU.
5
4. The GCU as claimed in claims 1 to 3, wherein the master unit constantly
monitors and determines whether values of the operating parameters of the engine
and the alternator of each genset are within a range set for the specific genset.
10 5. The GCU as claimed in claims 1 and 4, wherein if the master unit determines
that the values of the operating parameters of the genset are not within the set range
of the genset, the GCU indicates and displays an alert message to the user through
the user interface or automatically stops the operation of the genset.
15 6. The GCU as claimed in claim 1, wherein if the master unit detects any AMF
and/or synchronisation failures from the genset, the GCU indicates and displays an
alert message to the user through the user interface or automatically stops the
operation of the genset.
20 7. The GCU as claimed in claim 1, wherein the auxiliary units are
communicatively coupled with one or more coolant and oil heaters of the gensets
through different sensors to maintain preset temperature of coolant and oil in the
gensets and to provide ON/OFF command to the heaters.
25 8. The GCU as claimed in any of the preceding claims, wherein the user
interface is designed as a human machine interface (HMI) touch screen display such
that the user communicates with the GCU to select and activate at least one of
auto/manual operating modes for starting or stopping the operation of the gensets.
48
9. The GCU as claimed in any of the preceding claims, wherein the HMI touch
screen display is configured to display warning messages, alarms and shutdown
messages of the gensets.
5 10. The GCU as claimed in any of the preceding claims, wherein the master unit
is communicatively coupled to a circuit breaker of each of the gensets any one of the
communication protocols to automatically start or stop the operation of the gensets.
11. The GCU as claimed in claim 1, wherein the GCU is interfaced with a remote
10 monitoring system and a service tool through the communication units via one of
the communication protocols.
12. The GCU as claimed in any of the preceding claims, wherein the
communication units comprise CAN (Controller Area Network) ports, UART
15 (Universal Asynchronous Receiver/Transmitter) ports, serial ports, MODBUS ports,
Ethernet ports, and Wi-Fi module, and
the communication protocols comprise CAN bus, UART communication,
serial communication, MODBUS, Ethernet, GSM (Global System for Mobile
Communications) communication.
20
13. The GCU as claimed in any of the preceding claims, wherein the operating
parameters of the engine and the alternator of the gensets comprise engine voltage,
engine current, engine frequency, engine phase angle, engine speed, engine power
factor, engine lube oil pressure, engine coolant level, engine battery voltage, engine
25 coolant temperature, alternator voltage, alternator current, alternator frequency,
alternator phase angle, and alternator power factor.
14. The GCU as claimed in claim 1, wherein the master unit is communicatively
coupled with an after treatment system controller through one of the
30 communication protocols for deciding and controlling urea dosing in an exhaust
system of the gensets.
49
15. A method for integrated handling of multiple gensets with different
operational requirements for power generation application, comprising:
receiving and storing, by a memory device of a genset controller unit (GCU),
a plurality of operating parameters, a plurality of fault parameters and a plurality of
5 user setting parameters in accordance with each genset along with its operational
requirements through a plurality of communication units, wherein the plurality of
communication units is configured to communicate with a plurality of genset
components and a plurality of external devices using different communication
protocols;
10 monitoring and controlling, by a master unit of the GCU, the operating
parameters of an engine and an alternator of each genset, wherein the master unit
is communicatively coupled with the engine, the alternator and an electronic control
unit (ECU) of each genset through at least one of the communication units;
monitoring and controlling, by one or more auxiliary units of the GCU,
15 ON/OFF state of one or more supplementary components of the gensets to maintain
preset temperature and supplementary constraint for operation of the gensets;
regulating, by the master unit, the operating parameters of each genset to
synchronize the operational requirements of each of the gensets;
determining, by the master unit, auto mains failure (AMF) by continuously
20 monitoring mains voltage from a mains voltage terminal to automatically start the
gensets if mains supply is failed or cut off; and
displaying the operating, fault and user setting parameters of the gensets,
on at least one user interface being connected with the master unit and the auxiliary
units of the GCU.
25
16. The method as claimed in claim 15, further comprising: synchronizing, by
the master unit, different types and ratings of the gensets by determining at least the
operating parameters of voltage, frequency and phase angle of the gensets.
30 17. The method as claimed in claims 15 and 16, further comprising: after
synchronizing each of the gensets, operating, by the master unit, each genset in a
50
load sharing mode for controlling genset load based on ratings of the gensets, and a
load demand mode for controlling genset load based on an external input into the
GCU.
5 18. The method as claimed in claims 15 to 17, further comprising: constantly
monitoring and determining, by the master unit, whether values of the operating
parameters of the engine and the alternator of each genset are within a range set for
the specific genset.
10 19. The method as claimed in claims 15 and 18, further comprising: if the values
of the operating parameters of the genset are not within the set range of the genset,
indicating and displaying an alert message to the user through the user interface or
automatically stopping the operation of the genset.
15 20. The method as claimed in claim 15, further comprising: detecting, by the
master unit, any AMF and/or synchronisation failures from the genset, and if the
AMF and/or synchronisation failures are detected, indicating and displaying an alert
message to the user through the user interface or automatically stopping the
operation of the genset.
20
21. The method as claimed in claim 15, wherein the auxiliary units are
communicatively coupled with one or more coolant and oil heaters of the gensets
through different sensors to maintain preset temperature of coolant and oil in the
gensets and to provide ON/OFF command to the heaters.
25
22. The method as claimed in any of the preceding claims, wherein the user
interface is designed as a human machine interface (HMI) touch screen display such
that the user communicates with the GCU to select and activate at least one of
auto/manual operating modes for starting or stopping the operation of the gensets.
30
51
23. The method as claimed in any of the preceding claims, wherein the HMI
touch screen display is configured to display warning messages, alarms and
shutdown messages of the gensets.
5 24. The method as claimed in any of the preceding claims, wherein the master
unit is communicatively coupled to a circuit breaker of each of the gensets any one
of the communication protocols to automatically start or stop the operation of the
gensets.
10 25. The method as claimed in claim 15, wherein the GCU is interfaced with a
remote monitoring system and a service tool through the communication units via
one of the communication protocols.
26. The method as claimed in claim 15, wherein the communication units
15 comprise CAN (Controller Area Network) ports, UART (Universal Asynchronous
Receiver/Transmitter) ports, serial ports, MODBUS ports, Ethernet ports, and Wi-Fi
module, and
the communication protocols comprise CAN bus, UART communication,
serial communication, MODBUS, Ethernet, GSM (Global System for Mobile
20 Communications) communication.
27. The method as claimed in any of the preceding claims, wherein the
operating parameters of the engine and the alternator of the gensets comprise
engine voltage, engine current, engine frequency, engine phase angle, engine speed,
25 engine power factor, engine lube oil pressure, engine coolant level, engine battery
voltage, engine coolant temperature, alternator voltage, alternator current,
alternator frequency, alternator phase angle, and alternator power factor.
28. The method as claimed in claim 15, wherein the master unit is
communicatively coupled with an after treatment system controller through one of
the communication protocols for deciding and controlling urea dosing in an exhaust
system of the gensets.