Rotor-Mounted Alternator Controller Eliminates External Current Transformers
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Solution Overview
Problem
Current current transformers used in engine-generator sets are expensive, bulky, and labor-intensive to install, with a high risk of errors, necessitating a more efficient and cost-effective alternative for measuring alternator current.
Innovation Solution
A rotor-mounted controller system that includes a rotor assembly with a rotor controller, sensor, and communication device, which measures and adjusts generator parameters such as field winding current and prime mover speed to maintain optimal output voltage and frequency, eliminating the need for current transformers by directly monitoring and controlling alternator performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If current transformers are used to measure alternator current, then measurement capability is provided, but device cost, size, and installation complexity increase significantly
Solution Approach 1:
The patent extracts the current measurement function from the traditional current transformer and integrates it directly into the rotor assembly. The rotor-mounted controller with its sensor system performs current measurement internally, eliminating the need for separate external current transformers and their associated installation complexity.
Solution Approach 2:
The patent combines the current measurement function with the rotor controller assembly. The controller, already present for field winding control, is enhanced with sensor capabilities to simultaneously perform current measurement, merging two functions into one integrated system rather than using separate components.
2Measurement precision
If current transformers are used to measure alternator current, then measurement capability is provided, but installation labor and error risk increase
Solution Approach 1:
The rotor-mounted controller system is self-contained and requires no external installation of current transformers. The system uses its own integrated sensors and processing capabilities to perform measurements, making the installation process simpler and reducing the risk of installation errors associated with external current transformer mounting and wiring.
3Device complexity
If rotor-mounted controller with sensors is used instead of current transformers, then installation complexity is reduced, but new control system components are required
Solution Approach 1:
The rotor controller assembly is designed to serve multiple functions: it controls the field winding and simultaneously measures alternator current using integrated sensors. This multi-functionality reduces the need for separate dedicated components and simplifies the overall system architecture, making it easier to manufacture as a unified assembly.
Data Source
AI summary
In one embodiment, a generator includes a rotor configured to rotate in cooperation with a stator to generate electrical power. A sensor, which is supported by the rotor, is configured to generate a trigger signal indicative of a position of the rotor. A communication interface is configured to receive the trigger signal from the sensor of the rotor and receive data indicative of an output of the generator. A controller supported by the rotor or configured to perform a phase analysis of the trigger signal and the output of the generator and calculate a power angle for the generator based on the phase analysis.