Variable Speed Genset Hybrid Power System for Off-Grid Efficiency

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Solution Overview

Problem

Conventional hybrid genset systems for off-grid applications are inefficient and costly due to oversized gensets and batteries, leading to significant energy loss and high maintenance costs, and are unreliable when primary renewable power sources are unavailable, with issues of power fluctuations and voltage incompatibility.

Innovation Solution

A hybrid power system incorporating a primary renewable power source, an energy storage device, a variable speed genset, and a central controller that adjusts power sources and generator speed based on load requirements, using power electronic systems to match voltage and frequency to load needs, and employing a fuel map for optimal fuel consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If synchronous-speed gensets are used with FPMRT strategy, then genset efficiency is maintained and machine wear is limited, but oversized batteries are required which significantly increase system cost and energy loss

Engineering Contradiction:
Improvegenset efficiencyVSAvoidenergy loss
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The patent applies variable speed technology to the genset, allowing the rotor speed to vary dynamically based on load conditions rather than operating at fixed synchronous speed. This enables the genset to operate efficiently across a range of loads without requiring FPMRT strategy, thereby reducing the need for oversized batteries and associated energy losses.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent changes the operating parameters of the genset by allowing speed variation instead of maintaining fixed synchronous speed. This parameter change enables the system to adapt to varying load conditions efficiently, eliminating the need for oversized batteries and reducing energy loss during charging cycles.

Inventive Principle:
Principle #35Parameter changes

2Power

If synchronous-speed gensets are oversized to meet peak loads, then peak power requirements are satisfied, but the genset operates at low efficiency during partial loading

Engineering Contradiction:
Improvepeak power outputVSAvoidfuel consumption
Core Design Contradiction:
PowerVSUse of energy by moving object

Solution Approach 1:

The variable speed genset can dynamically adjust its rotor speed to match the actual load requirements. During peak loads, the genset operates at high speed to meet power demands, and during partial loading, it automatically reduces speed to maintain optimal efficiency, thereby reducing fuel consumption without sacrificing peak power capability.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

By changing the rotor speed parameter dynamically rather than maintaining fixed synchronous speed, the genset can operate at optimal efficiency points across varying load conditions while still being capable of meeting peak power requirements when needed.

Inventive Principle:
Principle #35Parameter changes

3Stability of the object's composition

If fixed synchronous speed is used, then voltage and frequency are stable, but the system cannot adapt to varying load requirements efficiently

Engineering Contradiction:
Improvevoltage stabilityVSAvoidload adaptability
Core Design Contradiction:
Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The variable speed genset dynamically adjusts rotor speed in response to varying load conditions while power electronic systems maintain stable voltage and frequency output. This dynamic adaptation allows the system to efficiently match load requirements without compromising the stability of electrical parameters.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

Power electronic systems act as intermediaries between the variable speed genset and the load, converting the variable speed output into stable voltage and frequency. This intermediary conversion enables both load adaptability and electrical stability to coexist in the system.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 reduces energy losses, lowers maintenance costs by avoiding oversized batteries, ensures reliable power supply, and optimizes fuel efficiency by matching genset output to load demands, while providing compatible voltage and frequency for off-grid applications.

Implementation Method 1

a variable speed generator coupled to a prime mover of the secondary power source, the variable speed generator configured to convert the power provided by the prime mover to electrical power at a variable speed

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a power electronic system configured to convert the electrical power provided by the variable speed generator to a voltage and a frequency required by a load

Methodology Applied
Scientific EffectElectrical conversion:

Implementation Method 3

an energy storage device coupled to the primary power source, the energy storage device configured to store excess primary power provided by the primary power source

Methodology Applied
Scientific EffectEnergy storage:

Data Source

PatentUS8987939B2Hybrid power system with variable speed genset
Publication Date: 2015.03.24 CATERPILLAR INC
  • US8987939B2 patent drawing
  • US8987939B2 patent drawing
  • US8987939B2 patent drawing

AI summary

A hybrid power system is disclosed. The hybrid power system may include a primary power source configured to provide a primary power, and an energy storage device coupled to the primary power source, the energy storage device configured to store excess primary power provided by the primary power source. The hybrid power system may further include a variable speed genset, the variable speed genset including a secondary power source configured to operate at a variable rotor speed to provide a secondary power responsive to power requirements of a load. The hybrid power system may also include a central controller communicatively coupled to the primary power source, the energy storage device, and the variable speed genset, the central controller configured to control the primary power source, the energy storage device, and the variable speed genset based on the power requirements of the load.