Generator Set Calibration Controller Automatic Error Adjustment
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Solution Overview
Problem
Existing calibration methods for genset controllers are time-consuming and lack accuracy, relying on manual processes and potentially inaccurate test points, which are not specifically applicable to genset controllers and may not adequately address scale and time delay errors introduced by sensing components and transformers.
Innovation Solution
A calibration controller with a memory module storing calibration factors for offset, scale, and time delay errors, and a processor that monitors electric power parameters to detect connection with a load and adjust these factors automatically, performing both initial and secondary calibrations to improve measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration process is used, then operator control is maintained, but calibration time is excessive and accuracy is insufficient
Solution Approach 1:
The calibration system performs automatic calibration without requiring manual intervention. The processor automatically compares monitored power parameters with expected values, calculates error values, determines adjustments, and updates calibration factors autonomously, eliminating the need for technician involvement while achieving high accuracy and speed
Solution Approach 2:
The patent replaces the manual mechanical calibration process with an automated electronic system. The processor module electronically compares measurements, calculates corrections, and adjusts calibration factors through software algorithms, substituting the manual mechanical adjustment process with automated electronic computation and control
2Measurement precision
If test points are selected for calibration, then calibration can be performed, but accuracy is insufficient if test points are not optimally selected
Solution Approach 1:
The system continuously monitors power parameters during calibration and provides feedback to the processor. The processor uses this feedback to compare actual measurements with expected values, calculate error values, and iteratively adjust calibration factors until optimal accuracy is achieved, ensuring precise error determination regardless of initial test point selection
Solution Approach 2:
The calibration process is dynamic rather than static. The system automatically selects and adjusts test points based on the calibration progress and error values calculated. The processor dynamically modifies the calibration approach by selecting additional test points or adjusting measurement parameters to optimize accuracy without requiring complex pre-planning
3Measurement precision
If expected values are used for comparison during calibration, then calibration can be performed, but accuracy deteriorates if expected values do not match actual values
Solution Approach 1:
The system introduces a high-accuracy reference power meter as an intermediary during calibration. This reference meter provides authoritative measurement values that serve as the ground truth for comparison. The processor uses these reference measurements to calculate accurate error values and determine precise calibration adjustments, eliminating reliance on potentially inaccurate expected values
Solution Approach 2:
The system performs preliminary calibration using stored calibration factors before actual operation. During this preliminary phase, the processor compares measurements against reference values and pre-calculates adjustment values that will be applied during normal operation. This preliminary action ensures that the calibration account for actual system characteristics rather than relying on theoretical expected values
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 solution enables automatic calibration processes that reduce operator time and improve measurement accuracy by selecting optimal sample points and comparing monitored values with high-accuracy meter readings, enhancing genset power monitoring and regulation precision.
Implementation Method 1
one or more current and/or voltage transformers may be used to step down the voltage and current to lower levels
Data Source
AI summary
A controller for a generator set is disclosed. The controller may have a memory module having stored therein calibration factors associated with an offset error, a scale error, and a time delay error, and a processor module in communication with the memory module. The processor module may be configured to monitor at least one parameter of electric power directed from the generator set to a load, detect connection of the generator set to the load, and determine adjustments to the calibration factors after connection of the generator set to the load based on a comparison of the at least one parameter monitored by the processor module and measured at the load.