Generator system, power distribution unit for a generator, and a method of controlling power allocation from a generator to a load

Abstract

A generator system for distributing power to a load includes an engine, a generator coupled to the engine, a power regulator, a power distribution unit, and an aftertreatment system. The power regulator is configured to regulate power form the generator to a power output. The generator-integrated power distribution unit includes a distribution unit housing and a gate driver. The distribution unit housing is mounted to the generator. The gate driver is disposed within the distribution unit housing. The aftertreatment system includes a heater coupled to the generator by a power distribution unit. The gate driver is configured to control allocation of power from the power output to the heater.

Description

GENERATOR SYSTEM, POWER DISTRIBUTION UNIT FORA GENERATOR, AND A METHOD OF CONTROLLING POWER ALLOCATION FROM A GENERATOR TO A LOADCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 554,796, filed February 16, 2024, the entire contents of which are hereby incorporated by reference herein.TECHNICAL FIELD

[0002] The present disclosure relates to systems and methods for generating and distributing power from a generator.BACKGROUND

[0003] Generator systems for vehicles and other equipment can include one or more onboard generators to power one or more vehicle loads. For example, the generator systems can be used to power heating of an aftertreatment system, which can include one or more components (e.g., catalysts, etc.) that must be maintained above threshold temperatures to ensure compliance with emissions requirements such as limits on particulate and exhaust gas emissions set forth by government agencies.SUMMARY

[0004] One embodiment of the present disclosure relates to a generator-integrated power distribution unit. The generator-integrated power distribution unit includes a generator and a power distribution unit. The power distribution unit includes a distribution unit housing, a power regulator, and a plurality of gate drivers. The distribution unit housing is mounted to the generator. The power regulator is disposed within the distribution unit housing and is configured to regulate power from the generator to a power output. The plurality of gate drivers are also disposed within the distribution unit housing. The plurality of gate drivers areconfigured to control allocation of the power output from the power regulator to a plurality of loads.

[0005] Another embodiment of the present disclosure relates to a generator system including an engine; a generator coupled to the engine; a power regulator configured to regulate power from the generator to a power output; a power distribution unit; and an aftertreatment system. The power distribution unit includes a distribution unit housing mounted to the generator and a gate driver disposed within the distribution unit housing. The aftertreatment system includes a heater coupled to the generator by a power distribution unit. The gate driver is configured to control allocation of power from the power output to the heater.

[0006] Still another embodiment of the present disclosure relates to a power distribution unit for a generator. The power distribution unit includes a distribution unit housing and a gate driver. The distribution unit housing defines an interior cavity. The distribution unit housing includes a controller input, a power input, and a power output disposed on the distribution unit housing. The gate driver is disposed within the interior cavity. A first input to the gate driver is coupled to the power input. A second input to the gate driver is coupled to the controller input. An output to the gate driver is coupled to the power output.

[0007] Still another embodiment of the present disclosure relates to a method of controlling power allocation from a generator to a load. The method includes receiving power from the generator at a power input disposed on a distribution unit housing of a power distribution unit that is mounted to the generator; receiving, by a gate driver disposed within the distribution unit housing, a control signal from a control input disposed on the distribution unit housing; and supplying, by the gate driver, the power from the generator to a power output on the distribution unit housing responsive to the control signal.

[0008] Still another embodiment of the present disclosure relates to a generator system including and engine; an aftertreatment system coupled to the engine; a generator coupled to the engine; and a power distribution unit. The aftertreatment system includes a heater (or multiple heaters) configured to heat exhaust gas received from the engine. The powerdistribution unit is mounted to the generator and is configured to control allocation of power from the generator to the heater.

[0009] These and other features, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings.BRIEF DESCRIPTION OF THE FIGURES

[0010] The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several implementations in accordance with the disclosure and are therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings.

[0011] FIG. 1 is a block diagram of an exhaust aftertreatment heating system inclusive of a generator-integrated power distribution unit, according to an embodiment.

[0012] FIG. 2 is a circuit diagram of an exhaust aftertreatment heating system inclusive of a generator-integrated power distribution unit, according to another embodiment.

[0013] FIG. 3 is a circuit diagram of an exhaust aftertreatment heating system inclusive of a generator-integrated power distribution system, according to still another embodiment.

[0014] FIG. 4 is a table showing a plurality of operating states for the generator-integrated power distribution units of FIG. 2 and FIG. 3.

[0015] FIG. 5 is a circuit diagram of a generator- integrated power distribution unit for an exhaust aftertreatment system coupled to multiple heat loads, according to an embodiment.

[0016] FIG. 6 is a circuit diagram of the generator-integrated power distribution unit of FIG. 5 coupled to a single heat load, according to an embodiment.

[0017] FIG. 7 is an exploded view of an exhaust aftertreatment system inclusive of a generator-integrated power distribution unit, according to an embodiment.

[0018] FIG. 8 is a perspective view of a generator system used in the exhaust aftertreatment system of FIG. 7, inclusive of a smart alternator and a generator- integrated power distribution unit, according to an embodiment.

[0019] FIG. 9 is an exploded view of an exhaust aftertreatment system inclusive of a generator-integrated power distribution unit, according to an embodiment.

[0020] FIG. 10 is a perspective view of a generator system used in the exhaust aftertreatment system of FIG. 9, inclusive of a motor-generator unit and a generator-integrated power distribution unit, according to an embodiment.

[0021] FIG. 11 is a flow diagram of a method of controlling activation and / or power allocation to a load using a generator-integrated power distribution unit, according to an embodiment.

[0022] Reference is made to the accompanying drawings throughout the following detailed description. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative implementations described in the detailed description, drawings, and claims are not meant to be limiting. Other implementations may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and made part of this disclosure.DETAILED DESCRIPTION

[0023] Embodiments described herein relate to a generator-integrated device for controlling the distribution of power to multiple loads onboard a vehicle or in another generator-powered application. In at least one embodiment, the generator-integrated power distribution device isconfigured to generate power and control the allocation of power to multiple heaters of an aftertreatment system for an internal combustion engine system. The power distribution device is integrated into the generator and defines an output of the generator that is connectable to the various loads.

[0024] In some embodiments, the power distribution device includes multiple gate drivers to control allocation of power between two loads with different power requirements. Such an arrangement can eliminate the need for separate power distribution and control equipment for the heaters, and can enable use of the generator-integrated system in different applications without having to modify the generator or onboard circuitry. Additionally, by integrating the power distribution device with the generator, systems and methods of the present disclosure can reduce the overall volume of space required for generator hardware and control equipment, and can eliminate the need for cooling equipment for the power distribution circuitry that is separate from cooling equipment onboard the generator. Furthermore, the use of gate drivers enables automatic load control without the use of switches and other moving components, which can improve the overall service life and durability of the system, and can eliminate the need for a separate battery to control operation of the power distribution device (i.e., to eliminate the need to power switches, such as solenoids, and other power control circuitry to control activation and allocation of power to one or more loads).

[0025] Referring to FIG. 1, a generator-integrated power distribution system is shown as generator system 100, according to an embodiment. The generator system 100 is configured to generate power, and to selectively control the allocation of power to a plurality of loads.

[0026] In the embodiment of FIG. 1, the generator system 100 (which may also be referred to as a generator-integrated power distribution system) includes an engine 101; a generator 108 coupled to the engine 101; a power regulator 114 that is configured to regulate power from the generator 108 to a power output 118; a power distribution unit 102; an aftertreatment system, shown as a generator load 104; and an engine control module 106. The power distribution unit 102 includes a distribution unit housing 112 mounted to the generator 108 and a gate driver 116 disposed within the distribution unit housing 112. The generator load 104 (the aftertreatment system) includes a heater that is coupled to the generator by the power distribution unit 102.The gate driver 116 is configured to control allocation of power from the power output 118 to the generator load 104 (e.g., the heater). In other embodiments, the generator system 100 includes additional, fewer, and / or different components.

[0027] In some embodiments, the generator system 100 includes the engine 101; an aftertreatment system (e.g., the generator load 104) coupled to the engine 101; the generator 108 coupled to the engine 101; and the power distribution unit 102. The aftertreatment system includes a heater (or multiple heaters) configured to heat exhaust gas received from the engine101. The power distribution unit 102 is mounted to the generator 108 and is configured to control allocation of power from the generator 108 to the heater.

[0028] The engine 101 (which may also be referred to as an engine system) is configured to power the generator 108 to produce electricity (e.g., power). In some embodiments, the engine 101 includes a diesel engine. In other embodiments, the engine 101 may include a gasoline engine, a natural gas engine, a dual fuel engine, a biodiesel engine, an E85 engine, a flex fuel engine, a gas turbine, or another type of internal combustion engine or driver. The engine may be used to power a truck, a boat, a locomotive, or another type of vehicle (e.g., an on-road or off-road vehicle). In yet other embodiments, the engine may be used in an industrial application to drive a pump, hydraulic system, or another type of system. The engine 101 may be coupled to the generator by a clutch, belt drive, or another type of connection.

[0029] The power distribution unit 102 (which may also be referred to as a generator- integrated power distribution unit, a generator-integrated power distribution circuit, and / or generator- integrated power distribution module) includes the distribution unit housing 112 and the gate driver 116. The distribution unit housing 112 is mounted to the generator 108. The gate driver 116 is disposed within the distribution unit housing 112. The gate driver 116 is configured to control allocation of power from the power output 118 (e.g., from the power regulator 114) to a load 120. In the embodiment of FIG. 1, the power distribution unit 102 includes a plurality of gate drivers 116 that are disposed within the distribution unit housing 112. In some embodiments, the power regulator 114 forms part of the power distribution unit102. In some embodiments, the power regulator 114 is disposed within the distribution unit housing 112.

[0030] The generator 108 (e.g., alternator, smart alternator, motor generator, electrical power generator, etc.) is configured to produce electrical power from a mechanical input. In at least one embodiment, the generator 108 is an alternator for an internal combustion engine system that is configured to generate electrical power from rotational energy produced by the engine system. For example, the generator 108 can includes a claw pole machine generator having a rotor with claw shaped poles or another stator-rotor arrangement.

[0031] In another embodiment, the generator 108 is or includes a motor generator unit that integrates a motor and a generator into a single device. For example, the motor generator unit may be part of a hybrid vehicle generator that is used to convert electrical power to mechanical output to power the wheels of the hybrid vehicle or another mechanically operated device. In some embodiments, the generator 108 is a smart alternator including a brushed, air-cooled or liquid-cooled motor. As used herein, “smart alternator” refers to a variable voltage alternator that can be controlled, such as via a power regulator as described in further detail herein, to provide different voltage output to various loads.

[0032] In some embodiments, the generator 108 includes a stator and a rotor that is rotatably coupled to the stator and that moves relative to the stator to convert a mechanical input to electrical power. The generator 108 also includes a generator housing 122 (e.g., a generator enclosure, etc.) and output terminals 124, which form a power input 117 to the power distribution unit 110. In the embodiment of FIG. 1, the output terminals 124 are disposed on the generator housing 122. In some embodiments, the generator housing 122 defines an internal cavity that is configured to house the stator, the rotor, and optionally the output terminals 124 therein. In some embodiments, the generator housing 122 defines a power distribution unit mounting flange configured to engage with and mount the distribution unit housing 112 of the power distribution unit 110 to the generator housing 122.

[0033] In the embodiment of FIG. 1, the generator housing 122 is mounted to the distribution unit housing 112 so that the distribution unit mounting flange engages the distribution unit housing 112. The generator housing 122 supports the distribution unit housing 112 in fixed position with respect to the generator 108 to thereby form a generator- integrated unit / module.

[0034] The power distribution unit 110 (e.g., a power distribution circuit, a power distribution module, etc.) is configured to control allocation of power from the generator 108 to the plurality of loads 120.

[0035] The power distribution unit 110 includes the distribution unit housing 112 and the gate driver 116. The distribution unit housing 112 defines an interior cavity 113. The distribution unit housing 112 includes a controller input 115, a power input 117, and a power output 119 disposed thereon. The gate driver 116 is disposed within the interior cavity 113. A first input 121 of the gate driver 116 is coupled (e.g., electrically, communicab ly) to the controller input 115. A second input to the gate driver 116 is coupled to the controller input 115. An output 123 of the gate driver 116 is coupled to the power output 119.

[0036] In some embodiments, and as will be further described, the power distribution unit 110 is mounted internal to the generator housing 122 (e.g., so that the power distribution unit 110 is disposed substantially within the generator housing 122). In other embodiments, the power distribution unit 110 is mounted to the generator housing 122 external to the internal volume of the generator housing 122 (e.g., to the top of the generator housing 122, to the back of the generator housing 122, etc.). As used herein, the term “mounted” encompasses any arrangement in which the power distribution unit 110 is physically connected to, and at least partially supported by, the generator 108, and is not limited to external mounting arrangements of the power distribution unit 110 (or distribution unit housing 112) on the outer surface of the generator 108. In other embodiments, the power distribution unit 110 is built into the power regulator 114 (e.g., into a regulator housing of the power regulator 114) and / or forms part of the power regulator 114.

[0037] In the embodiment of FIG. 1, the power distribution unit 110 includes a distribution unit housing 112 mounted to the generator housing 122 (e.g., the distribution unit mounting flange) proximate to the output terminals 124, such as along the distribution unit mounting flange that circumscribes the output terminals 124. An input of the power distribution unit 110 is electrically coupled to the output terminals 124. The power distribution unit 110 is integrated with the generator 108 so that the power distribution unit 110 defines a power output

[0038] The power distribution unit 110 may be air-cooled or liquid-cooled in various embodiments and depending on application requirements. The power regulator 114 may also be air-cooled or liquid-cooled along with, or separately from, the power distribution unit 110. In some embodiments, the power distribution unit 110 shares the same cooling system as the generator 108 and / or the power regulator 114, which can reduce system complexity.

[0039] In the embodiment of FIG. 1, the power regulator 114 is communicab ly coupled to the engine control module 106 and controls an amount of power provided by the power distribution unit 102 to the load 120. In some embodiments, the power regulator 114 is communicab ly coupled to the engine control module 106 by a controller area network (CAN) bus system. In other embodiments, the generator system 100 utilizes another type of communication protocol to exchange information / instructions between various components (e.g., a local interconnect network (LIN), a CAN flexible data-rate (CAN-FD), or another type of propriety or industry standard communication protocol now know or hereinafter developed).

[0040] Referring to FIG. 2 and FIG. 3, different configurations of a generator-integrated power distribution unit for a generator system are shown. In the embodiment of FIG. 3, the generator system 200 includes a generator 202 and a power distribution unit 204 including a power regulator 206.

[0041] In the embodiment of FIG. 2, the generator 202 is a smart alternator and the power regulator 206 includes a regulator 207. The regulator 207 is configured to control voltage output from the smart alternator based on commands from an engine control unit during operation. In at least one embodiment, the regulator 207 is configured to provide power within a range between approximately 0-20kW per load (e.g., per heater of the aftertreatment system, etc.). In another embodiment, the regulator 207 may be configured to provide power from the generator 108 to the power distribution unit 110 in a range from about 0-5kW per load, 0- lOkW per load (e.g., l-10kW per load or OkW (OFF)), 0-1000KW per load, or any range between and including the foregoing values.

[0042] In some embodiments, the load 120 includes one or more heaters that are configured to adjust the temperature of the exhaust gas passing through the exhaust aftertreatment system.For example, the heater(s) may be a resistive heater that is electrically controlled to vary the temperature of the exhaust gas and / or a component of the aftertreatment system.

[0043] In some embodiments, the power distribution unit 204, either alone or in combination with the power regulator 206, is configured to provide variable power from the generator to the load, and / or to control activation of the load (e.g., to power the load on and off). For example, in an embodiment in which the power distribution unit 204 controls power allocation to multiple loads, the power distribution unit 204 may be configured to power each of the loads (e.g., heaters) with up to 5kW heat per load, either simultaneously, or at different power levels to each load. Such control may be variable (e.g., providing power at any level within the range of approximately 0-5kW) or fixed (e.g., enabling activation of the load(s) at a single fixed power level, such as lOkW fixed power level to each load during operation). In some embodiments, the power distribution unit 204 is configured to provide variable control over the power levels to a first load of the plurality of loads, and a fixed power level to a second load of the plurality of loads (e.g., supplying fixed power to a 3kW heater and variable power to a 5kW heater, etc.).

[0044] In other embodiments, the power distribution unit 204 is configured to provide variable power levels, such as between 0-5kW, or another range (as described above) to a single load (e.g., a single heater. In another embodiment in which the power distribution unit 204 controls power allocation to a single load, the power distribution unit 204 may be configured to provide a fixed power level of 3kW or another fixed power level to the load when activated (e.g., to control activation of the load between an off condition (at OkW) and an on condition (at 3kW) without enabling operation at intervening power levels between 0 and 3kW).

[0045] The power distribution unit 204 is electrically coupled to the load(s) by a load communication system (e.g., a CAN BUS, etc.) that is separate from the communication system used between the engine control module and the power regulator (or the power distribution unit 204). In such embodiments, the load communication system is a dedicated communication network between the power distribution unit 204 and the load(s), which can enable retrofit ofexisting systems to include a generator-integrated power distribution unit 204 and simplify integration into the generator system.

[0046] In other embodiments, the power distribution unit 204 is coupled to the shared communication system (e.g., vehicle BUS) and may be used to power other loads of the generator / vehicle system. For example, the power distribution unit 204 may be used to control activation and / or allocation of power to one or more batteries onboard the vehicle, e- accessories, e-axles, vehicle propulsion systems, and other components. Such an arrangement can enable improved utilization of generator power, such as by the batteries and / or accessories onboard the vehicle, when the load(s) (e.g., the heaters for the aftertreatment system) are not being used.

[0047] The power distribution unit 204 includes a distribution unit housing 208, the power regulator 206, and electronic circuit components including a plurality of gate drivers 210, a plurality of diodes 212, and a plurality of sensors 214. The power distribution unit 204 also includes a power output 216 including a plurality of first terminals 218 (e.g., a plurality of negative terminals) and a second terminal 220 (e.g., a positive terminal) that are together configured to electrically couple the smart alternator to a plurality of loads 222. The second terminal 220 is configured to form a closed circuit with each of the plurality of first terminals 218.

[0048] The distribution unit housing 208 defines an internal volume for housing the electrical components and circuitry of the power distribution unit 204 therein. In some embodiments, the power regulator 206, the plurality of gate drivers 210, the plurality of diodes 212, and the plurality of sensors 214 are disposed within the power distribution unit 204. In other embodiments, at least one component of the power distribution unit 204 is disposed at least partially within the generator housing or in a regulator housing disposed between the generator housing and the distribution unit housing 208.

[0049] The plurality of gate drivers 210, the plurality of diodes 212, and the plurality of sensors 214 form part of an electronic circuit for the power distribution unit 204. In some embodiments, the power distribution unit 204 also includes a printed circuit board includingwire traces that electrically couple the plurality of gate drivers 210, the plurality of diodes 212, and the plurality of sensors 214 to one another, and to the power output 216.

[0050] In the embodiment of FIG. 2, the plurality of gate drivers 210, the plurality of diodes 212, and the plurality of sensors 214 together define two circuits (e.g., two closed loops, etc.), shown as first circuit 224a and second circuit 224b arranged in a parallel circuit arrangement. In other embodiments, the power distribution unit 204 may include additional circuits.

[0051] In the embodiment of FIG. 2, the first circuit 224a and the second circuit 224b include the same components arranged in the same way. The first circuit 224a includes a first gate driver 210a (one of the gate drivers 210), a first sensor 214a (one of the sensors 214), and a first diode 212a (one of the diodes 212). The first circuit 224a is electrically coupled to the first gate driver 210a of the plurality of gate drivers 210. The second circuit 224b is electrically coupled to a second gate driver 210b of the plurality of gate drivers 210.

[0052] The first gate driver 210a is configured to control switching of power to activate and deactivate resistive loads. In some embodiments, the first gate driver 210a includes MOSFETs to control activation of the first circuit 224a based on an input from the engine control unit. In some embodiments, the engine control unit is configured to use pulse-width modulation (PWM) to modulate the opening and closing of the MOSFETs to thereby adjust time averaged load on each heater (e.g., power output to the heater(s)). In such embodiments, the power distribution unit may be used independently from a power regulator, while still enabling allocation of various power levels and control states for the heater(s). For example, the engine control unit may be configured to adjust the average load on each heater by varying the actuation frequency of the MOSFETs and / or signal amplitude provided from the generator to one or more loads. Such an approach can provide additional control over the average load provided by each circuit to each heater and can enable a continuous adjustment of heater power (e.g., to any value between approximately 0-20kW or another power range) based on application requirements.

[0053] The plurality of first terminals 218 are each coupled (e.g., electrically) to a respective one of the plurality of gate drivers 210. In the embodiment of FIG. 2, an input 226a of the firstgate driver 210a is coupled to an output 228a of the regulator 207. An output 230a of the first gate driver 210a is coupled to a respective one of the first terminals 218, shown as first terminal 218a.

[0054] The plurality of sensors 214 are each communicab ly coupled to a respective one of the first circuit 224a or the second circuit 224b (e.g., one or a combination of the first circuit 224a or the second circuit 224b) and are configured to generator sensor data indicative of a current (or other electrical parameter associated with circuit operation) passing through the respective one of the first circuit 224a or the second circuit 224b. The first sensor 214a is configured to determine a current of the first circuit 224a. In some embodiments, the first sensor 214a is a current transducer configured to produce sensor data indicative of a real-time current passing through the first circuit 224a. The first sensor 214a is disposed between the first gate driver 210a and the first terminal 218a. In other embodiments, the location of the first sensor 214a along the first circuit 224a may be different.

[0055] Each one of the plurality of diodes 212 is coupled between a respective one of the plurality of gate drivers 210 and the second terminal 220. The first diode 212a is connected (e.g., electrically) between the first terminal 218a of the plurality of terminals 218 and the second temiinal 220. The first diode 212a is configured to provide electronic circuit protection in the event of a power surge or other power event.

[0056] The first load 222a and the second load 222b are electrically coupled to a respective one of the two circuits. In the embodiment of FIG. 2, the first load 222a is electrically coupled between the first terminal 218a of the first terminals (e.g., an output of the first gate driver 210a) and the second terminal 220. The second load 222b is electrically coupled between a second terminal 218b of the first terminals and the second terminal 220. In the embodiment of FIG. 2, the first load 222a and the second load 222b are represented as resistive loads (e.g., resistors) connected between a respective one of the first terminals and the second terminal.

[0057] Referring to FIG. 3, another generator-integrated power distribution unit 300 is shown, according to an embodiment. The generator-integrated power distribution unit 300 includes a generator 302 and a power distribution unit 304 including a power regulator 306.

[0058] In the embodiment of FIG. 3, the generator 302 is a motor generator unit and the power regulator 306 includes an inverter 307. The inverter 307 is configured to control voltage and / or current output from the motor generator unit based on commands from an engine control unit. The inverter is also configured to convert alternating current from the motor generator unit (i.e., the generator 302) to direct current for powering the loads. In at least one embodiment, the inverter 307 is configured to provide power within a range between approximately 0-20kW per load (e.g., per heater of the aftertreatment system, etc.), or various other ranges as discussed above with respect to FIG. 2.

[0059] The generator-integrated power distribution units (e.g., the plurality of gate drivers) of FIGS. 2 and 3 are both reconfigurable between at least four operating states so as to power different ones of the plurality of loads. Referring to FIG. 4, a table 400 showing each of the four operating states and their associated load is shown, according to an embodiment. In a first state, both the first gate driver and the second gate driver are controlled (e.g., both DI and D2 high) to power both the first load and the second load. In a second state, the first gate driver and the second gate driver are controlled (e.g., DI high and D2 low) to power only the first load. In a third state, the first gate driver and the second gate driver are controlled (e.g., DI low and D2 high) to power only the second load. In a fourth state, the first gate driver and the second gate driver are controlled (e.g., both DI and D2 low) to deactivate both the first and second loads.

[0060] The operating states of the generator-integrated power distribution unit enables operation at multiple voltage and current levels to control operation of different combinations of loads. For example, in the embodiment of FIG. 4, the first load may be different from the second load such that the gate drivers are together configured to control allocation of the power output between a first load of the plurality of loads and a second load of the plurality of loads at a higher voltage than the first load.

[0061] Referring again to FIG. 1, the generator load 104 includes an exhaust aftertreatment system for an internal combustion engine system. The exhaust aftertreatment system may include a diesel particulate filer, catalysts, and / or other components to reduce harmful gas and particulate matter emissions from the exhaust system. In some instances, and in particular forlarge diesel engine systems, the aftertreatment system may include multiple portions in the form of a plurality of legs that are arranged in parallel to increase the overall flow capacity for the aftertreatment system.

[0062] In the embodiment of FIG. 1 , the exhaust aftertreatment system includes a plurality of electrical loads 120 in the form of heaters, shown as a first heater 126a and a second heater 126b, for an exhaust aftertreatment system (e.g., heaters that are configured to heat different parts of the aftertreatment system, or that are configured to provide different levels of heat to the aftertreatment system). The heaters can be used to reduce cold start exhaust emissions, improve regeneration performance, and / or to improve operating performance for various applications in different operating environments.

[0063] It should be appreciated that the generator-integrated power distribution systems described herein may be used to power other loads and / or different types of loads for a vehicle or other generator-powered system in other embodiments.

[0064] The engine control module 106 (e.g., a control unit, a controller, a control circuit, etc.) is configured to control operation of the power distribution unit 102 (e.g., the power distribution unit 110). The engine control module 106 is electrically coupled to the power distribution unit 110 via the power regulator 144. In other embodiments, as shown in FIG. 1, the engine control module 106 is communicably coupled to the gate driver 116 (or the plurality of gate drivers) and is configured to control operation of the gate driver 116. For example, the engine control module 106 may be configured to control operation of the gate driver 116 using pulse-width modulation (PWM) techniques to adjust the power provided to the load without the use of moving components, as will be further described. In such embodiments, power allocation to the load(s) may be performed without a power regulator 114. In some embodiments, the engine control module 106 is also configured to control operation of the internal combustion engine, aftertreatment system, and / or other vehicle components.

[0065] The engine control module 106 includes a controller having memory storing machine-readable instructions thereon, and a processor communicably coupled to the memory and configured to execute the machine-readable instructions. In some embodiments, theprocessor is also communicably coupled to one or more sensors, such as temperature sensors configured to provide an indication of the environmental condition at one or more portions of the aftertreatment system. In other embodiments, the sensors may include contaminant sensors such as NOx sensors, CO2 sensors, or another type of exhaust gas sensor.

[0066] The processor (e.g., the controller, the control circuit, etc.) may be configured to control operation of the power distribution unit 102 to satisfy one or more thresholds stored in memory based on the sensor data from the sensor(s). For example, the processor may be configured to determine a threshold temperature at which at least a portion of the aftertreatment system should operate based on sensor data from the one or more sensors, such as by referencing a lookup table in memory, or via another control algorithm stored in memory.

[0067] The various embodiments shown and described in the present application should not be considered limiting. Various alterations and alternatives are possible without departing from the inventive principles described herein. For example, referring to FIG. 5, a generator system 500 is shown that is configured to control activation and allocation of power to multiple loads, shown as heaters 520, without the use of a power regulator device, according to an embodiment. The generator system 500 includes a power distribution unit 510 that is controlled by an engine control module 506 using pulse-width modulation to adjust power levels provided to the heaters 520. Referring to FIG. 6, the power distribution unit 510 is also configured to control activation and allocation of power to a single heater 520 depending on application requirements, and by controlling a single gate driver within the power distribution unit 510.

[0068] The arrangement of the power distribution unit relative to the generator housing may also be different in various embodiments. For example, referring to FIG. 7, an engine exhaust aftertreatment system 601 for a vehicle is shown, according to an embodiment. The engine exhaust aftertreatment system 601 includes multiple heaters 620 configured to control temperatures of the exhaust gases passing through different parts of the engine exhaust aftertreatment system 601 (e.g., a first module 603 of the engine exhaust aftertreatment system 601, a second module 605 of the exhaust aftertreatment system, a particulate filter, a catalyst,etc.). Referring to FIG. 8, a generator system 600 for the engine exhaust aftertreatment system 601 is shown, according to an embodiment.

[0069] The generator system 600 includes a generator 608 including a generator housing 622; and power distribution unit 610 that is disposed within an interior cavity, shown as housing cavity 611 defined by the generator housing 622. In some embodiments, and as shown, the power distribution unit 610 includes a distribution unit housing 612 that is disposed substantially within the housing cavity 611. A power output of the power distribution unit extends through a rear wall of the generator housing 622 for access to electrically couple the generator 608 and the power distribution unit 610 to the heaters 620 (see also FIG. 7).

[0070] Referring to FIG. 9, another embodiment of an engine exhaust aftertreatment system 701 is shown. The engine exhaust aftertreatment system 701 is arranged similar to the engine exhaust aftertreatment system 601 of FIG. 7. The engine exhaust aftertreatment system 701 includes multiple heaters 720 and a generator system 700 powering the heaters 720. Referring to FIG. 10, a power distribution unit 710 of the generator system 700 is mounted externally along the generator housing 722, to an upper wall of the generator housing 722. In other embodiments, the power distribution unit 710 may be located along another portion or sidewall of the generator housing 722.

[0071] Referring to FIG. 11, a method 800 of controlling power allocation from a generator to a load is provided, according to an embodiment. The method includes receiving power from the generator at a power input disposed on a distribution unit housing of a power distribution unit that is mounted to the generator (802); receiving, by a gate driver disposed within the distribution unit housing, a control signal from a control input disposed on the distribution unit housing (804); and supplying, by the gate driver, the power from the generator to a power output on the distribution unit housing responsive to the control signal (806).

[0072] The method 800 may be performed by any of the generator systems described herein and will be described using the same terminology for equipment of the generator system. In other embodiments, the method 800 may include additional, fewer, and / or different operations.

[0073] At operation 802, a generator-integrated power distribution unit receives power from a generator. In some embodiments, operation 802 includes receiving the power from the generator at a power input disposed on a distribution unit housing of the power distribution unit that is mounted to the generator. The distribution unit housing may be mounted external to an interior cavity of the generator housing, or within the interior cavity, in various embodiments. In some embodiments, operation 802 includes receiving power directly from the generator. In other embodiments, operation 802 includes receiving power from a power regulator that is electrically connected between the generator and the power distribution unit.

[0074] At operation 804, the power distribution unit receives a control signal from a control module (e.g., an engine control module, etc.). In some embodiments, operation 804 includes receiving the control signal at a control input that is disposed along the distribution unit housing. In some embodiments, operation 804 includes receiving the control signal from the control input at a gate driver disposed within the distribution unit housing. In some embodiments, operation 804 includes receiving a pulse-width modulated control signal that is based on a desired power allocation to one or more loads that are connected to the power distribution housing.

[0075] At operation 806, the power distribution unit supplies (e.g., allocates, etc.) power from the generator to a power output on the distribution unit housing. In some embodiments, operation 806 includes controlling operation of a gate driver to activate a circuit within the power distribution unit and to supply power to the power output. In some embodiments, operation 806 further includes supplying the power from the generator to the load based on the pulse-width modulated control signal received by the gate driver. Operation 806 may include providing power to one or more heaters using any of the power arrangements described with respect to FIGS. 1 and 2 above.

[0076] It should be noted that although the diagrams herein may show a specific order and composition of processes, it is understood that the order of these processes may differ from what is depicted. For example, two or more processes may be performed concurrently or with partial concurrence. Also, some method processes that are performed as discrete processes may be combined, processes being performed as a combined step may be separated intodiscrete processes, the sequence of certain processes may be reversed or otherwise varied, and the nature or number of discrete processes may be altered or varied. The order or sequence of any element or apparatus may be varied or substituted according to alternative embodiments. Accordingly, all such modifications are intended to be included within the scope of the present disclosure as defined in the appended claims. Such variations will depend on the machine- readable media and hardware systems chosen and on designer choice. It is understood that all such variations are within the scope of the disclosure.

[0077] The various concepts discussed herein may be implemented in any of numerous ways, as the described concepts are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided for illustrative purposes.

[0078] Various numerical values herein are provided for reference purposes. Unless otherwise indicated, all numbers expressing quantities of properties, parameters, conditions, and so forth, used in the specification and claims are to be understood as being modified in all instances by the term “approximately.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations. Any numerical parameter should at least be construed in light of the number reported significant digits and by applying ordinary rounding techniques. The term “approximately” when used before a numerical designation, e.g., a quantity and / or an amount including range, indicates approximations which may vary by ( + ) or ( - ) 10%, 5%, or 1%.

[0079] As will be understood by one of skill in the art, for any and all purposes, particularly in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc. As will also be understood by one skilled in the art all language such as “up to,” “at least,” “greater than,” “less than,” and the like include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member.

[0080] The foregoing description of embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from this disclosure. The embodiments were chosen and described in order to explain the principals of the disclosure and its practical application to enable one skilled in the art to utilize the various embodiments and with various modifications as are suited to the particular use contemplated. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the embodiments without departing from the scope of the present disclosure as expressed in the appended claims.

Claims

WHAT IS CLAIMED IS:

1. A generator system comprising: an engine; a generator coupled to the engine; a power regulator configured to regulate power from the generator to a power output; a power distribution unit, including: a distribution unit housing mounted to the generator; and a gate driver disposed within the distribution unit housing; and an aftertreatment system comprising a heater coupled to the generator by the power distribution unit, the gate driver configured to control allocation of power from the power output to the heater.

2. The generator system of claim 1, wherein the heater is one of a plurality of heaters, and the gate driver is one of a plurality of gate drivers reconfigurable between at least four operating states so as to power different ones of the plurality of heaters.

3. The generator system of any one of the proceeding claims, wherein the generator comprises a generator housing, the power output comprises output terminals disposed on the generator housing, the distribution unit housing mounted to the generator housing proximate to the output terminals.

4. The generator system of claim 1, wherein the gate driver is one of a plurality of gate drivers disposed within the distribution unit housing, wherein the heater is one of a plurality of heaters that are each electrically coupled to the generator by a respective one of plurality of gate drivers.

5. The generator system of claim 4, wherein the plurality of gate drivers are configured to control allocation of the power output between a first heater of the plurality of heaters and a second heater of the plurality of heaters at a higher voltage than the first heater.

6. The generator system of claim 1, wherein the heater is configured to adjust the temperature of exhaust gas passing through the aftertreatment system.

7. The generator system of claim 1, wherein the generator is one of a motor generator unit or an alternator, and wherein the power regulator includes one of an inverter electrically coupled to the motor generator unit, or a regulator electrically coupled to the alternator.

8. The generator system of any one of claims 1, 2, 4, 6, or 7, further comprising a controller communicably coupled to the gate driver and configured to control operation of the gate driver using pulse-width modulation to adjust the power provided to the heater.

9. The generator system of claim 1, wherein the power distribution unit is configured to enable activation of the heater without a battery.

10. The generator system of any one of claims 1, 2, 4, 6, 7, and 9, wherein the gate driver is one of a plurality of gate drivers, and wherein the power distribution unit further comprises: a first circuit electrically coupled to a first gate driver of the plurality of gate drivers; a second circuit electrically coupled to a second gate driver of the plurality of gate drivers; and plurality of sensors each communicably coupled to a respective one of the first circuit or the second circuit and configured to generate sensor data indicative of a current passing through the respective one of the first circuit or the second circuit.

11. The generator system of any one of claims 1, 2, 4, 6, 7, and 9, wherein the generator comprises a generator housing, and wherein the power distribution unit is disposed at least partially within the generator housing.

12. A power distribution unit for a generator, the power distribution unit comprising: a distribution unit housing defining an interior cavity, the distribution unit housing comprising a controller input, a power input, and a power output disposed thereon; and a gate driver disposed within the interior cavity, a first input to the gate driver coupled to the power input, a second input to the gate driver coupled to the controller input, and an output to the gate driver coupled to the power output.

13. The power distribution unit of claim 12, wherein the gate driver forms part of a first circuit that extends through the power distribution unit, further comprising a sensor disposedwithin the distribution unit housing and communicably coupled to the first circuit, the sensor configured to generate sensor data indicative of a current passing through the first circuit.

14. The power distribution unit of any one of claims 12 or 13, wherein the power output comprises a plurality of terminals that are configured to be coupled to at least one electrical load, the power distribution unit further comprising a diode electrically coupled between a first terminal of the plurality of terminals and the second terminal of the plurality of terminals.

15. The power distribution unit of claim 12, wherein the gate driver is one of a plurality of gate drivers disposed within the interior cavity and electrically coupled between the power input and the power output, the power output comprising a plurality of terminals each coupled to a respective one of the plurality of gate drivers.

16. The power distribution unit of claim 15, wherein the plurality of terminals comprises: a plurality of first terminals; and a second terminal that is configured to form a closed circuit with each of the plurality of first terminals.

17. The power distribution unit of claim 16, further comprising a plurality of diodes each coupled between a respective one of the plurality of gate drivers and the second terminal.

18. The power distribution unit of any one of claims 12 or 13, wherein the gate driver includes a MOSFET configured to enable selective control of the power supplied to the power output by pulse-width modulation techniques without the use of moving components.

19. A method of controlling power allocation from a generator to a load, the method comprising: receiving power from the generator at a power input disposed on a distribution unit housing of a power distribution unit that is mounted to the generator; receiving, by a gate driver disposed within the distribution unit housing, a control signal from a control input disposed on the distribution unit housing; and supplying, by the gate driver, the power from the generator to a power output on the distribution unit housing responsive to the control signal.

20. The method of claim 19, wherein receiving the control signal comprises receiving a pulse-width modulated signal, further comprising supplying the power from the generator to the load based on the pulse-width modulated signal.

21. A generator system comprising: an engine; an aftertreatment system coupled to the engine, the aftertreatment system comprising a heater configured to heat exhaust gas received from the engine; a generator coupled to the engine; and a power distribution unit mounted to the generator, the power distribution unit electrically coupled to the heater and configured to control allocation of power from the generator to the heater.

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