DC Bus Voltage Feedback for Automatic Generator Power Control

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Solution Overview

Problem

Conventional generator systems lack automatic power control, leading to inefficient fuel consumption and potential overloading in direct current microgrids due to intermittent power generation and voltage instability, especially during grid outages or when connected to unreliable electric grids.

Innovation Solution

A direct current microgrid system with a generator system that automatically adjusts power production based on desired and actual voltage levels, using an engine, alternator, converter system, and controller to maintain stable voltage by producing electricity when needed and ceasing production when voltage is sufficient, thereby optimizing fuel usage and preventing overloading.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the generator operates continuously to ensure power supply, then reliability of power delivery is improved, but fuel consumption increases and overloading risk occurs

Engineering Contradiction:
Improvepower supply reliabilityVSAvoidfuel consumption
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The controller continuously monitors the actual voltage of the DC bus and compares it with the desired voltage, automatically adjusting generator operation based on real-time conditions. This feedback mechanism ensures the generator operates only when needed (when voltage drops below desired level) and stops when voltage is sufficient, maintaining reliability while eliminating unnecessary fuel consumption.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The system transitions from static continuous operation to dynamic conditional operation. The generator's operational state changes dynamically based on real-time voltage conditions, allowing it to switch between operating and stopped states optimally, thereby ensuring power reliability when needed while reducing fuel waste during sufficient voltage conditions.

Inventive Principle:
Principle #15Dynamics

2Reliability

If the generator automatically turns on during outages, then power supply reliability is improved, but the system complexity increases

Engineering Contradiction:
Improvepower supply reliabilityVSAvoidcontrol system complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The generator system performs self-monitoring and self-action through the controller that automatically detects voltage drops and activates the generator without human intervention. The system serves itself by having the controller continuously monitor DC bus voltage and autonomously decide when to start or stop the generator, ensuring reliability while keeping the control logic relatively simple and direct.

Inventive Principle:
Principle #25Self-service

3Reliability

If the generator operates when voltage is already sufficient, then power supply reliability is maintained, but harmful overloading effects occur

Engineering Contradiction:
Improvepower supply stabilityVSAvoidoverloading damage
Core Design Contradiction:
ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The controller uses real-time voltage feedback from the DC bus to determine generator operation. When the actual voltage meets or exceeds the desired voltage, the controller stops the generator, preventing overloading. When voltage drops below the desired level, the controller activates the generator to restore voltage. This feedback-based control eliminates harmful overloading while maintaining power stability.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The system establishes a predetermined desired voltage level as a threshold before operation begins. By comparing actual voltage against this pre-set threshold, the controller can proactively prevent overloading conditions before they occur, while also ensuring reliability by activating the generator in advance when voltage approaches critical levels.

Inventive Principle:
Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system ensures reliable and stable power delivery in direct current microgrids by automatically adjusting power production, reducing fuel waste and preventing overloading, while maintaining optimal voltage levels, thus enhancing the overall functionality and efficiency of generator systems.

Implementation Method 1

an alternator operable to convert the mechanical energy generated by the engine to electricity

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a converter system operable to: convert alternating current electricity to direct current electricity

Methodology Applied
Scientific EffectRectification:

Data Source

PatentUS20240413643A1Generator system with automatic power control
Publication Date: 2024.12.12 GENERAC POWER SYSTEMS INC
  • US20240413643A1 patent drawing
  • US20240413643A1 patent drawing
  • US20240413643A1 patent drawing

AI summary

This disclosure is directed to generator systems and methods for monitoring a direct current bus and automatically operating in response to a power level of the direct current bus dropping below a desired power level or to a threshold before dropping below the power level. The automatic operation of the generator system may raise or keep the actual power level of the system above the desired power level or threshold.