Generator Breaker Control Using Solid-State PQM Switching

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Solution Overview

Problem

Conventional power quality monitors and DPDT relays in generator control units face challenges in reliability, stability, and complexity, with performance variations due to temperature and voltage levels, necessitating improved solutions.

Innovation Solution

A power quality monitor module utilizing a solid-state semiconductor switch with differential amplifiers, comparators, and logic detectors, replacing mechanical relays to enhance response time and reliability, and including a NOT gate and ORing diode circuit for efficient control of a generator control breaker.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a mechanical DPDT relay is used in the power quality monitor, then the device can be manufactured with conventional components, but the response time varies with temperature and voltage levels and the reliability is reduced

Engineering Contradiction:
ImprovereliabilityVSAvoidcomplexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical DPDT relay with a solid-state semiconductor switch (such as a MOSFET or IGBT). This substitution eliminates the mechanical moving parts that cause reliability issues under varying temperature and voltage conditions. The solid-state switch provides consistent electrical control without the wear, contact bounce, or thermal expansion problems inherent in mechanical relays, thereby significantly improving reliability while maintaining functional equivalence in the generator control circuit.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

2Speed

If a mechanical DPDT relay is used in the power quality monitor, then the device structure is simple, but the response time is slow and varies with operating conditions

Engineering Contradiction:
Improveresponse timeVSAvoidperformance variation
Core Design Contradiction:
SpeedVSObject-affected harmful factors

Solution Approach 1:

The mechanical relay is replaced with a solid-state semiconductor switch that responds instantaneously to electrical control signals. This eliminates the mechanical actuation delay and contact movement time inherent in relays. The solid-state device provides consistent response time across the full operating range of temperature and voltage, eliminating the performance variation that occurs with mechanical components subjected to environmental stress.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If additional circuit components (differential amplifier, comparator, logic detector) are added to the PQM module, then the control precision and reliability are improved, but the device complexity increases

Engineering Contradiction:
ImprovestabilityVSAvoidcomplexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent integrates multiple functional components (differential amplifier, comparator, logic detector, and solid-state switch) into a single unified PQM module. This consolidation allows the circuits to work together in a coordinated manner with optimized signal flow and power management. The integrated design reduces the number of external connections and inter-component interfaces, thereby improving overall system stability and reliability while minimizing the increase in complexity compared to using separate discrete components.

Inventive Principle:
Principle #5Merging (Combining)

Data Source

PatentUS12007419B2Systems and methods for generator control
Publication Date: 2024.06.11 HAMILTON SUNDSTRAND CORP
  • US12007419B2 patent drawing

AI summary

A power quality monitor (PQM) module includes a solid-state semi-conductor switch having a voltage input, two signal inputs and two voltage outputs. A voltage input line is electrically connected to the voltage input. A PQM signal input line is operatively connected to at least one of the two signal inputs. A voltage output line is electrically connected to one of the two voltage outputs to provide power to a load. A method of controlling a GCB includes opening a solid-state semi-conductor switch when a PQM signal is powered at a first logic voltage. The method includes closing the solid-state semi-conductor switch when a PQM signal is powered at a second logic voltage lower than the first logic voltage to allow a voltage from a GCU to go to the GCB.