Abstract:
A portable power system for use with an electrical device. The system includes a portable power storage device, a motor, a controller, an alternator, an inverter, and a first monitor. The portable power storage device provides a DC voltage. The first monitor generates a first indication related to a characteristic of the portable power source. The controller monitors the primary power source delivering primary power to the electrical device, couples the portable power storage device to the inverter for generating an AC output, and selectively drives the motor in response to the first indication. The alternator is responsive to the motor for converting mechanical motion of the motor into an electrical signal for use to recharge the portable power storage device.

Description:
RELATED APPLICATIONS 
     [Not Applicable] 
     FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     [Not Applicable] 
     MICROFICHE/COPYRIGHT REFERENCE 
     [Not Applicable] 
     BACKGROUND OF THE INVENTION 
     The invention relates to power distribution, and more particularly, to power distribution from a portable generator to an appliance. 
     When electricity supplied from a primary source to electrical appliances is disconnected, known standby generators are typically used as secondary power sources to provide secondary or backup power. However, these standby generators typically use combustion-engines and fossil fuel to drive the engines. In such cases, the cost of using standby generators to provide power is high due to rising fuel cost. Standby generators are also limited to outdoor usage due to toxic fume emission. In order to utilize these outdoor standby generators to provide power to mostly indoor appliances, numerous costly devices and interfaces between the standby generators and the indoor appliances are also required. 
     BRIEF SUMMARY OF THE INVENTION 
     Certain embodiments of the present invention provide backup power systems, and methods for providing backup power. 
     In one embodiment, the invention provides a portable power system for providing secondary power to an electrical device upon disconnection of a primary power source from delivering primary power to the electrical device. The system includes a portable power storage device, a motor, an alternator, an inverter, a first monitor and a controller. The portable power storage device provides a DC voltage. The motor is selectively driveable by the portable power storage device. The alternator is responsive to motor for converting mechanical motion of the motor into an electrical signal for use to recharge the portable power storage device. The inverter receives a DC voltage and generates an AC output for use to provide the secondary power to the electrical device. The first monitor generates a first indication related to a characteristic of the portable power source. The controller monitors the primary power source delivering primary power to the electrical device, couples the portable power storage device to the inverter for generating the AC output, and selectively drives the motor in response to the first indication. 
     In another embodiment, the invention provides a method for supplying secondary power to an electrical device upon disconnection of a primary power source from delivering primary power to the electrical device. The method includes monitoring the primary power source delivery primary power to the electrical device, coupling a portable power storage device to an inverter for generating an AC output for use to provide the secondary power to the electrical device, and monitoring a first indication related to a characteristic of the portable power storage device. The method also includes selectively driving the motor with the portable power storage device in response to the first indication, and converting mechanical motion of the motor into an electrical signal for use to recharge the portable power storage device. 
     In yet another embodiment, the invention provides a secondary power system integrated with an electrical device upon disconnection of a primary power source from delivering primary power to the electrical device through a device controller of the electrical device. The secondary power system includes a portable power storage device, a motor, a first sensing device, a control board, an alternator, and an inverter. The motor is selectively coupled to the portable power storage device. The first sensing device generates a first indication related to a characteristic of the secondary power system. The control board communicates with the device controller, selectively couples the portable power storage device to the motor in response to the primary power being disconnected from the primary source and thereby drives the motor in response to the first indication. The alternator is mechanically coupled to the motor and being driven by the motor. The alternator generates a direct-current signal. The inverter inverts the direct-current signal into an alternating-current signal and thereby provides the secondary power. 
    
    
     
       BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a block diagram of a portable power system according an embodiment of the invention. 
         FIG. 2  is a first exemplary schematic of the portable power system as shown in  FIG. 1 . 
         FIG. 3  is a second exemplary schematic of the portable power system integrated with a furnace as shown in  FIG. 1 . 
         FIG. 4  is an operation flow chart of the portable power system of  FIG. 1  used in accordance with embodiments of the present invention. 
     
    
    
     The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, certain embodiments are shown in the drawings. It should be understood, however, that the present invention is not limited to the arrangements and instrumentality shown in the attached drawings. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. 
     As should also be apparent to one of ordinary skill in the art, the systems shown in the figures are models of what actual systems might be like. Some of the modules and logical structures described are capable of being implemented in software executed by a microprocessor or a similar device or of being implemented in hardware using a variety of components including, for example, application specific integrated circuits (“ASICs”). Terms like “processor” may include or refer to both hardware and/or software. Furthermore, throughout the specification capitalized terms are used. Such terms are used to conform to common practices and to help correlate the description with the drawings. However, no specific meaning is implied or should be inferred simply due to the use of capitalization. 
     Embodiments of the invention relate to a system for providing power to a connected appliance or device. The system includes a controller circuit that monitors power delivered to the device. The controller circuit connects a portable power storage device to the device, and to a motor thereby energizing the motor. In turn, the motor drives a power generating device to supply power to charge the portable power storage device. 
     Referring to  FIG. 1 , a portable power system  100  is connected to an electrical device  104  and to a primary power source  108 . Under normal operation, the primary power source  108  supplies power to operate the device  104 . Upon disconnection of the primary power source  108  from the device  104 , the system  100  supplies a secondary or backup power to the device  104 . Of course, the system  100  can also be used as a stand-alone power generator to supply primary power to the device  104 . Exemplary devices  104  include, but are not limited to, heating, ventilating, and air conditioning (“HVAC”) equipment, boilers, inflatable structures, recreational vehicle (“RV”) accessories, breathing apparatuses, construction appliances, electric vehicles, medical equipment, refrigeration systems, and the like. 
     The portable power system  100  includes a control board or controller  112  that controls and monitors operations of the portable power system  100 , as detailed hereinafter. In some embodiments, the controller  112  includes primary and secondary controllers (not shown in  FIG. 1 ), where the secondary controller is a redundant controller. The primary and secondary controllers are typically daisy-chained together, but other types of connections can also be used. In the event of a power outage or other issues associated with the primary controller, the secondary controller becomes a backup and will be activated to perform similar functions, until the primary controller is powered again. 
     The controller  112  is coupled to an interface  116  that allows interaction between a user and the portable power system  100 . In some embodiments, the interface  116  includes a power switch (not shown) for turning on the portable power system  100 , operational indicators (not shown), such as, for example, LEDs and a multi-meter for displaying operational information and statuses to the user, switches (not shown) allowing the user to diagnose system issues, switches/controls (not shown) allowing the user to troubleshoot the portable power system  100 , and communication ports (not shown), such as, for example, universal serial bus (“USB”) receptacles for receiving a USB plug such that operational information and/or diagnosis of the portable power system  100  can be downloaded or uploaded, as detailed hereinafter. In some embodiments, the operation information is stored in a memory (not shown) on the controller  112 . Exemplary memory includes, but is not limited to, a removable hard disk drive, a read only memory (“ROM”), a random access memory (“RAM”), a flash memory, and the like. In some embodiments, the controller  112  and the interface  116  are integrated as a single unit. In the embodiments in which the portable power system  100  provides the primary power to the device  104 , instead of the primary power source  108 , such as in an RV environment, the portable power system  100  also uses the interface  116  as a control interface for the user. 
     The portable power system  100  also includes a portable power storage device  120 , a motor  124 , a connecting device  128 , and a power generating device  132 . The portable power storage device  120  is a 12 VDC battery that produces a direct-current (“DC”) signal. An exemplary portable power storage device  120  is an Optima battery made by Johnson Controls, which produces a 780 A cranking current signal. In other embodiments, the portable power storage device  120  can be an alternating-current (“AC”) battery, which produces an AC signal output. It should be noted other battery sizes and capacities can be used depending on the particular applications. 
     The motor  124  is connected to the connecting device  128  which conveys the spinning motion and energy of the motor  124  to the power generating device  132 . In some embodiments, the motor  124  is a ⅓ horsepower and thermally protected motor having a minimum speed of 1725 RPM and a continuous duty of about 6.2 A, running on a 110 VAC circuit. Exemplary connecting devices  128  include, but are not limited to, pulleys, belts, gears, and the like. The power generating device  132  converts or translates the conveyed motion and energy of the motor  124  into electricity. The power generating device  132  includes an alternator  140 , a switching device  148 , and an inverting device  152 . Power is supplied to the inverting device  152  via the alternator  140  or via the portable power storage device  120 . The switching device  148  controllably connects the alternator  140  and/or the portable power storage device  120  to the inverting device  152 . 
     The power generating device  132  supplies the electricity to the device  104  via a socket or outlet  136  located on a panel of the portable power system  100 . Although the outlet  136  is described as located on the panel of the portable power system  100 , the outlet  136  can alternately be an electrical cord extending from the portable power system  100  directly into the electrical device  104 , or an electrical cord having an outlet to receive an electrical plug of the device  104 . Although the portable power system  100  is described as supplying a 110 VAC signal, the portable power system  100  can also be configured to supply a 220 VAC signal, or a combination of 110 VAC and 220 VAC signals. 
     The alternator  140  is generally sized and specified according to the particular application. Generally, alternators having higher amperages will be used for applications demanding more power. In some embodiments, the alternator  140  is a standard 2-wire Delco 105 Amp alternator. Under normal operating conditions, the Delco 105 Amp alternator supplies 60-70 Amps. However, when the device  104  is required to consume more energy than a Delco 105 Amp alternator can provide, other alternators can also be used. In such an event, an alternator having a capacity of, such as, for example, 200 A can be installed in place of the Delco 105 alternator. 
     When the alternator  140  receives the conveyed motion from the motor  124 , the alternator  140  translates the spinning motion into electricity. The electricity is regulated by the voltage regulator  144 . In the embodiment as shown in  FIG. 1 , the alternator  140  has an integrated voltage regulator  144 . In other embodiments, the voltage regulator  144  can be a separate component connected to the alternator  140 . 
     The output of the voltage regulator  144  is connected to the portable power storage device  120  via switching device  148 . When the output voltage of the portable power storage device  120  drops below a predetermined voltage threshold, such as, for example, 11.5V, as monitored by the controller  112 , the controller  112  activates the switching device  148  to provide the voltage regulated output of the voltage regulator  144  to the portable power storage device  120 , to recharge the portable power storage device  120 . When the output voltage of the portable power storage device  120 , as monitored by the controller  112 , is above another predetermined voltage threshold, such as, for example, 13V, the controller  112  activates the switching device  148  to disconnect the voltage regulator  144  from the portable power storage device  120 . In addition, the output of voltage regulator  144  is provided to the inverting device  152  so as to produce an AC current output. 
     The inverting device  152  includes one or more inverters  156  depending on the particular application. For example, low amperage inverters will be used for applications that require only low amperage output. For another example, both high and low amperage inverters will be used for applications that require both low and high amperage outputs. For another example, where the device  104  is a boiler, or any device requiring less than about 18 A, inverters  156  running at about 2K Watts can be used. Existing forced air furnaces may require inverters of about 3K Watts. Field work such as construction work sites may require inverters of about 5K Watts, or an inverter combination of 2K and 3K Watts. In addition, 220 VAC inverters can be used for applications such as central air units. 
     In some embodiments, the output of the inverting device  152  is surge protected. The inverted output from the inverter  156  is directly supplied to the outlet  136 . In one embodiment, the inverter  156  is a PEAK 2000 W inverter from Old World Industries, rated at 25 A, and having an 11-14.5 VDC input and generating a 120 VAC output. In some embodiments, the inverter  156  provides no less than about 16.6 A with a surge capacity of about 33.2 A. 
     The switching device  148  receives control signals from the controller  112  in order to (1) control the timing of recharging the portable power storage device  120 , and (2) control the timing of output of electrical power via the outlets  136 . The switching device  148  connects and/or disconnects the portable power storage device  120  to or from the power generating device  132 , and connects and/or disconnects the outlet  136  to or from the power generating device  132 . 
     In some embodiments, the alternator  140  may take a transient time to generate an amount of electricity that can be inverted by the inverting device  152 . The controller  112  determines (1) whether the motor  124  is spinning at a frequency or speed that is higher than a predetermined frequency or speed threshold, or (2) whether the alternator  140  through the voltage regulator  144  is generating an amount of electricity that is above a predetermined electricity threshold, or (3) whether the output voltage of the portable power storage device  120  is within an operational range, such as, for example, 11.5V and 13V, or (4) whether the inverting device  152  is generating an output that is above another predetermined electrical threshold. Exemplary electrical thresholds include, but are not limited to, wattage thresholds, amperage thresholds, and voltage thresholds. In some embodiments, a voltage threshold of 120 VAC is monitored at the outputs of the inverting device  152 . When the monitored inverted output at the inverting device  152  drops below 120 VAC, the controller  112  disconnects the inverting device  152  from the outlet  136 . Similarly, in other embodiments, when portable power storage device  120  generates an output of less than 11.5 VDC, the controller  112  also turns off the inverting device  152 . 
     In some embodiments, the portable power system  100  includes one or more frequency or speed sensors (not shown) that monitor the spinning frequency or the speed of the motor  124 , or sensor that monitor the movement of the connecting device  128 , and/or monitor the output of the alternator  140 . If the frequency or speed sensors indicate that the motor  124 , for example, is spinning at a particular speed, and if the controller  112 , upon receiving the particular speed, determines that the particular speed is above the predetermined speed threshold, the controller  112  via the switching device  148  disconnects the portable power storage device  120  from the voltage regulator  144 , stopping the portable power storage device  120  from being overcharged. This can enhance or maximize the life of the portable power storage device  120 . However, if the controller  112  determines that the particular speed is of the motor  124  below a predetermined speed threshold, the controller  112  via the switching device  148  continues to connect the output of the voltage regulator  144  to the portable power storage device  120 , and, thus recharges the portable power storage device  120 . Similarly, for example, if the controller  112  determines that the outputs of the alternator  140  are above a predetermined voltage threshold, the controller  112  via the switching device  148  closes a switch (not shown) that allows the alternator  140  to recharge the portable power storage device  120 . 
     For another example, if the controller  112  determines that outputs of the alternator  140  are above another predetermined voltage threshold, the controller  112  via the switching device  148  closes another switch (not shown) that allows the alternator  140  to provide the DC signals to the inverting device  152 , and thereby provide the backup power at the outlet  136 . In addition, the controller  112  via the switching device  148  closes another switch (not shown) that allows the portable power storage device  120  to provide DC signals to the inverting device  152 , and thereby provide backup power at the outlet  136 . Other functions of the controller  112  via the switching device  148  include manual operations of the portable power system  100 , and overriding operations of the inverting device  152  when an anomaly has been detected, or when the inverting device  152  requires a reset. 
     In some embodiments, the portable power system  100  can be integrated with the electrical device  104 , such as, for example, a furnace unit. In such cases, wirings of a device control  160  of the electrical device  104  are rewired to the controller  112 . When the primary power source  108  is disconnected from the electrical device  104 , the device control  160  communicates that event to the controller  112 . In turn, the controller  112  signals the switching device  148 , which connects the portable power storage device  120  to the motor  124  and to the power generating device  132  for generating electricity at the outlets  136 . Details of the operation are described hereinafter. 
     It should be noted that the portable power system  100  also includes other components not shown, such as, for example, temperature sensors placed therein to monitor temperatures of different components and of the portable power system  100 . In some embodiments, the monitored temperatures are recorded on the controller  112 . The portable power system  100  also includes venting grills to manage air flow in and out of the portable power system  100 , internal fans also to control air flow in and out of the portable power system  100 , and one or more slow-blow fuses placed between the alternator  140  and the inverting device  152  to prevent overloading or arching. 
       FIG. 2  illustrates an exemplary system  200  of the portable power system  100  of  FIG. 1 , wherein like numerals refer to like parts. The system  200  includes a motor  124  connected to an alternator  140  through a set of pulleys  204  and one or more belts  208 . In the embodiment shown, the controller  112  includes a primary control board  212  and a secondary control board  216 . In some embodiments, the secondary control board  216  is a redundant board that duplicates functions of the primary control board  212 . The portable power storage device  120  ( FIG. 1 ) is a battery  220 , and the inverting device  152  ( FIG. 1 ) includes two inverters  224 ,  228 . The outlet  136  ( FIG. 1 ) includes two subsets of outlets  232 ,  236 . The outlet  232  further includes two low amperage purge protected outlets  234  connected to the inverter  224 , whereas the outlet  236  includes four high amperage protected outlets  238  connected to the inverter  228 . 
     In some cases, devices connected to the high amperage protected outlets  238  demand more power, such that a certain amount of electrical current from the portable power storage device  220  is needed to drive the inverter  228 . In other cases, a certain amount of time is needed for the alternator  140  to reach a predetermined speed threshold prior to power can be drawn at the high amperage protected outlets  238 . A switch  242  is thus connected between the battery  220  and the inverter  228 , and provides a time delay at startups to build up the amount of current for the inverter  228 , or to allow the alternator  140  to reach the predetermined speed threshold. 
     Venting grills  240  are placed throughout the system  200  to control air flow in and out of the system  200 . The system  200  also includes sensors  244  which are placed throughout the system  200  to detect over heating. In some embodiments, the sensors  244  send temperature coded signals to the controllers  212 ,  216  such that the system  200  can be shut down in the event the interior temperature of the system  200  reaches a predetermined temperature threshold, and/or to turn on a plurality of cooling fans  248  to actively control the interior temperature. An interface  252  includes a USB port and a plurality of LEDs. 
     Similarly,  FIG. 3  illustrates another system  300  of the portable power system  100  of  FIG. 1 , wherein like numerals refer to like parts. The system  300  is integrated with a furnace  304  having a furnace control  308  (device control  160  of  FIG. 1 ). The system  300  includes a motor  124  connected to an alternator  140  through a set of pulleys  312  and belts  316 . In the embodiment shown, the controller  112  ( FIG. 1 ) includes a primary control board  320  and a secondary control board  324 . The portable power storage device  120  ( FIG. 1 ) is a battery  328 , and the inverting device  152  ( FIG. 1 ) includes one inverter  332 . The outlet  136  ( FIG. 1 ) includes an outlet  336 . The outlet  336  further includes four high amperage protected outlets  338  connected to the inverter  332 . A switch  336  is connected between the battery  328  and the inverter  332 . The switch  336  provides a time delay at startups, as discussed above, for example, so as to allow the motor  124  to reach a predetermined speed or frequency before connection of battery  328  to the inverter  332 . 
       FIG. 4  illustrates an operational flow chart  400  of the portable power system  100  of  FIG. 1 . At step  404 , the controller  112  detects whether a power outage has occurred by monitoring signal coming from the primary source  108  via the interface  116 . If the controller  112  determines that a power outage has occurred, the controller  112  instructs the switching device  148  to couple the portable power storage device  120  to the inverting device  152 , at step  408 . This in turn provides output power at the outlet  136  and to the motor  124 . 
     Upon connection of the portable storage device  120  to the inverting device  152 , the motor  124  is started, at step  412 . The controller  112  may also control any switch between the inverting device  152  and the motor  124 . The motor  124  in turn drives the alternator  140 , at step  416 . Outputs of the alternator  140  are regulated by the voltage regulator  144 , at step  420 . 
     The regulated alternator outputs are typically DC signals. The output of the regulator  144  charges the portable power storage device  120  with the regulated outputs, as described above. Additionally, both the regulated outputs and the outputs from the portable power storage device  120  are sent to the inverting device  152  and are inverted to AC signals, at step  424 . Alternatively, either only the regulated outputs or only the outputs from the portable power storage device  120  are sent to the inverting device  152  and are inverted to AC signals. 
     In some embodiments, the transmission of the inverted output signal to the outlet  136  may be switched or delayed. The controller  112  via sensors at the motor  124 , or at the voltage regulator  144 , determines whether the motor  124  is spinning at a predetermined speed threshold. In other embodiments, at step  428 , the controller  112  determines if a predetermined amount of time delay has elapsed. If such an initial threshold has been met as determined, at step  428 , the controller  112  via the switching device  148  supplies the AC signals to the outlet  136 , at step  432 . At step  436 , the controller  112  may at this time (instead of step  412 ) also supply the inverted output to the motor  124  via the switching device  148 . In addition, the controller  112  may control recharging of the portable power storage device  120  with the regulated outputs from the voltage regulator  144 , as described above, at step  440 . 
     The controller  112  continues to monitor additional thresholds, such as, for example, electrical thresholds, and speed or frequency thresholds, at steps  444  and  448 . As discussed above, exemplary electrical thresholds include, but are not limited to, wattage thresholds, amperage thresholds, and voltage thresholds. Exemplary frequency thresholds include motor speed thresholds, and alternator speed thresholds. 
     In some embodiments, the first and optional second thresholds at steps  444  and  448  form an operational output voltage range of the portable power storage device  120 . For example, the first threshold represents the output voltage of the portable power storage device and is 11.5V, and the second threshold represents the output voltage of the portable power storage device, and is 13V. As such, the portable power storage device  120  has an operational output voltage range between 11.5V and 13V. In such a case, if the controller  112  determines that the output voltage is below the first threshold, the controller  112  controls the recharging of the portable power storage device  120 . Otherwise, if the controller  112  determines that the output voltage is not below the first threshold, the controller  112  proceeds to determine if the output voltage is above the optional second threshold, at step  448 . 
     If the controller  112  determines the output voltage is below the second threshold at step  448 , the controller  112  controls the recharging of the portable power storage device  120 . If the controller  112  determines the output voltage is above the second threshold at step  448 , the controller  112  proceeds to disconnect the output of the voltage regulator  144  from the portable power storage device  120 , thereby stopping the portable power storage device  120  from being over-charged at step  452 , and to repeat step  404 . 
     While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.