Patent Abstract:
An integrated system for comprehensive control of an electric power generation system utilizes state machine control having particularly defined control states and permitted control state transitions. In this way, accurate, dependable and safe control of the electric power generation system is provided. Several of these control states may be utilized in conjunction with a utility outage ride-through technique that compensates for a utility outage by predictably controlling the system to bring the system off-line and to bring the system back on-line when the utility returns. Furthermore, a line synchronization technique synchronizes the generated power with the power on the grid when coming back on-line. The line synchronization technique limits the rate of synchronization to permit undesired transient voltages. The line synchronization technique operates in either a stand-alone mode wherein the line frequency is synthesized or in a connected mode which sensed the grid frequency and synchronizes the generated power to this senses grid frequency. The system also includes power factor control via the line synchronization technique or via an alternative power factor control technique. The result is an integrated system providing a high degree of control for an electric power generation system.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of co-pending U.S. application Ser. No. 09/535,541 filed Mar. 27, 2000, the teachings of which are incorporated herein by reference, which is a divisional of U.S. application Ser. No. 09/140,391 filed Aug. 26, 1998 now U.S. Pat. No. 6,072,302, the teachings of which also are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Technical Field of the Invention 
     This invention relates to control systems and methods for controlling inverter based electrical power generation and feeding of generated power to a grid. This invention particularly relates to an integrated control system and method that integrates a variety of power control functions including state machine control of distinct operational modes, synronization with the grid, power factor control and utility outage ride-through. 
     2. Description of Related Art 
     Various control devices for controlling inverter based electrical power generation are known in the art. Typical controllers utilize analog voltage or current reference signals, synchronized with the grid to control the generated wave form being fed to the grid. Such controllers, however, lack distinct control states and the capability of controlling transitions between specifically defined control states. 
     Various techniques for synchronizing the frequency of generated power to the frequency of a grid-are also known in the art. Such conventional line synchronizers typically sense the line frequency of the grid and lock to the grid when the generated frequency drifts into synchronization. 
     Such conventional line synchronizers, however, do not have the ability to control the rate of phase shift of the generated power or the ability to interface easily with both 50 Hz and 60 Hz grids. 
     Various techniques for controlling the power factor are also known in the art. In the context of electrical power generation, for example, Erdman, U.S. Pat. No. 5,225,712, issued Jul. 6, 1993, discloses a variable wind speed turbine electrical power generator having power factor control. The inverter can control reactive power output as a power factor angle or directly as a number of VARs independent of the real power. To control the reactive power, Erdman utilizes a voltage waveform as a reference to form a current control waveform for each output phase. The current control waveform for each phase is applied to a current regulator which regulates the drive current that controls the currents for each phase of the inverter. 
     Although the conventional art may individually provide some of these features, the combination of these features particularly when utilized in conjunction with an integrated system utilizing state machine control is not found in the art. 
     Other applications distinct from electrical power generation also utilize power factor control devices. For example, Hall, U.S. Pat. No. 5,773,955 issued Jun. 30, 1998, discloses a battery charger apparatus that controls the power factor by vector control techniques. The control loop utilized by Hall controls power delivery to the battery to obtain a desired charge profile by individually controlling the real and reactive components of the AC input current. The AC input current is forced to follow a reference that is generated in response to information received by the battery charge control circuit to supply the desired charging current to and remove discharge current from a battery. 
     SUMMARY AND OBJECTS OF THE INVENTION 
     An object of the invention is to provide an integrated system for controlling all aspects of inverter based electrical power generation and feeding of generated power to a grid. Another object of the invention is to provide a state machine having a plurality of defined control states for electric power transformation including a state controller that controls permitted transitions between the defined control states. 
     Another object of the invention is to provide a line synchronization technique that is highly flexible and permits synchronization with either a 50 Hz or 60 Hz grid as well as providing smooth transitioning from a stand-alone mode to a grid-connected mode. 
     A further object of the invention is to provide a line synchronization technique that can either sense the grid frequency or synthesize a frequency for electrical power generation. 
     Still another object of the invention is to control the re-synchronization rate to provide the smooth transition from stand-alone mode to a grid-connected mode. 
     A further object of the invention is to provide a method of controlling an electrical power generator during a utility outage. 
     Yet another object of the invention is to integrate the inventive method of utility outage ride-through with various other control techniques to provide an integrated system. 
     Still another object of the invention is to provide power factor control over generated electrical power wherein a simple DC control signal having two components commanding the real and reactive components of the generated power may be utilized to control the power factor. 
     The objects of the invention are achieved by providing a state machine having a plurality of control states for electric power transformation including an initialization state, a first neutral state, a pre-charge state, a second neutral state, an engine start state, a power on-line state, a power off-line state, and a shut down state wherein the state controller controls state transitions such that only permitted transitions between control states are allowed to occur. In this way, a high degree of control can be achieved for electrical power generating and feeding of electrical power to a grid. In this way, the safety and reliability of the system can be ensured. 
     The objects of the invention are further achieved by a method of controlling real and reactive power developed by a main inverter in an electrical power generation control device including the steps of sampling the three-phase currents output from the inverter, transforming the sampled three-phase current data to two-phase current data, transforming the two-phase current data to a rotating reference frame, controlling an output voltage according to a comparison result between a DC reference signal having real and reactive reference signal components, transforming the output voltage to a stationary reference frame, transforming the stationary reference frame output voltage to a three-phase reference signal, and controlling the inverter based on the three-phase reference signal. By utilizing such a control method, the DC reference signal can be input by an operator or a utility feeding the grid to thereby designate the real and reactive power output by the controlled inverter. 
     The objects of the invention are further achieved by providing a line frequency synchronization apparatus and method that utilizes a frequency sensor that samples the frequency of the grid or a synthesizer that synthesizes a grid frequency. In the case of sampled grid frequency, the frequency sensor signal is converted by an A/D converter that is controlled by initiating the conversion and reading of the digital value at a fixed frequency. This fixed frequency establishes the time base for which the invention can compute the actual frequency of the signal. This is further accomplished by determining when the falling or rising edge of the signal occurs and counting the number of samples therebetween. 
     In this way, a synchronization error signal is generated that can be utilized to bring the generated power into synchronization with a grid or the synthesized grid frequency. Furthermore, the synchronization shift rate is preferably limited in order to provide a smooth transition. 
     The objects of the invention are further achieved by providing a utility outage ride-through method and apparatus that detects a fault condition indicating that the electrical power generation device should be disconnected from the grid, opens a contactor that connects the device to the grid, clears a time counter, sets a mode to an off-line mode, commands the inverter within the device to perform off-line voltage control, and waits for a predetermined time period after all fault conditions have been cleared before setting the mode to an on-line current control mode, enabling the inverter and thereafter closing the contactor to reestablish the connection to the grid. 
     Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein: 
     FIG. 1 is a high-level block diagram illustrating the major components of a microturbine generator system that may be controlled according to the invention; 
     FIG. 2 is a high-level block diagram of a small grid-connected generation facility which is another example of a generation facility that may be controlled according to the invention; 
     FIG. 3 is a system block diagram of an electrical power generator according to the invention illustrating major components, data signals and control signals; 
     FIG. 4 is a detailed circuit diagram of a line power unit that may be controlled according to the invention; 
     FIG.  5 ( a ) is a state diagram according to a first embodiment of the invention that illustrates the control states and permitted control state transitions according to the invention; 
     FIG.  5 ( b ) is another state diagram illustrating a second embodiment according to the invention showing the control states and permitted control state transitions according to the invention; 
     FIG.  6 ( a ) is a block diagram illustrating a line synchronization apparatus according to the invention; 
     FIGS.  6 ( b )-( d ) illustrate synchronization and phase-shift angles in a coordinated diagram showing relative positions and transitions of the signals according to the invention; 
     FIGS.  7 ( a )-( b ) are flow charts illustrating the line synchronization method according to the invention; 
     FIG. 8 is a flow chart illustrating the utility outage ride-through method according to the invention; and 
     FIG. 9 is a control-loop block diagram illustrating the power factor control method according to the invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1 illustrates the major components of a line-power unit  100  containing the inventive control devices and methods and the overall relationship to a microturbine generator. As shown, the microturbine generator system includes two major components: the turbine unit  10  and the line-power unit  100  may be arranged as shown in FIG.  1 . 
     The turbine unit  10  includes a motor/generator  15  and an engine control unit  12 . The turbine unit  10  is supplied with fuel. For example, the motor/generator  15  may be constructed with an Allied Signal Turbo Generator™ which includes a turbine wheel, compressor, impeller and permanent magnet generator which are all mounted on a common shaft. This common shaft is supported by an air bearing which has a relatively high initial drag until a cushion of air is developed at which point the air bearing is nearly frictionless. 
     The motor (engine) in the motor/generator  15  is controlled by the engine control unit  12  which, for example, throttles the engine according to the demand placed upon the generator. Communication is provided between the turbine unit  10  and the line power unit  100  as shown by the control/data line connecting these units in FIG.  1 . This data includes operating data such as turbine speed, temperature etc. as well as faults, status and turbine output. 
     The motor/generator  15  supplies three-phase (3φ) electrical power to the line power unit  100  as further shown in FIG.  1 . The line power unit  100  also supplies three-phase auxiliary power (3φ Aux) to the turbine unit  10 . 
     The line power unit  100  contains three basic components. The line power unit controller  200 , starter  220  and utility interface  240  are all included within line power unit  100 . Furthermore, an operator interface that permits an operator to monitor and control the line power unit is further provided. The operator interface may include a front panel display for displaying critical operating data as well as controls such as a shut down switch and power level command input as further described below. 
     A DC bus supplies DC power to the line power unit  100  to permit off-grid starting of the turbine unit. Furthermore, the utility interface  240  supplies three-phase electrical power to the utility grid  99  as well as an optional neutral line. The line power unit  100  also receives utility authorization from a utility company which authorizes connection to the grid  99 . 
     FIG. 2 illustrates a small grid-connected generation facility showing some of the details of the components controlled by this invention. More particularly, a turbine generator  15  generates AC power that is supplied to rectifier  60 . The AC power is then converted into DC power by rectifier  60  and supplied to DC link consisting of DC bus  61  and capacitor  62  connected across DC bus  61 . 
     An inverter  70  transforms the DC voltage on the DC link into a three-phase AC waveform that is filtered by inductor  72  and then supplied to the utility  99  via contactor K 1 . 
     As further discussed below in relation to FIG. 3, the invention controls the inverter  70  and contactor K 1  as well as other components. FIG. 2 is actually a simplified diagram illustrating the necessary components for utility outage ride-through. Other components illustrated in FIGS. 3 and 4 are necessary for other types of control exercised by the invention such as power factor and synchronization. 
     FIG. 3 is a system block diagram illustrating a generation facility that may be controlled according to the invention. The generation facility includes a turbine generator  15  generating AC power supplied to rectifier  60 . This AC power is converted by rectifier  60  into DC voltage supplied to the DC link. This DC link may have the same construction as shown in FIG.  2 . The inverter  70  transforms DC power from the DC link into three-phase AC power that is fed to the grid  99  via inductor unit  72  and contactor K 1 . Power may also be supplied directly to the internal loads via a connection to the output of the inverter  70 . 
     The controller  200  receives a sensed voltage from the DC link as well as the output AC current from the inverter  70  as inputs thereto. The controller  200  utilizes these inputs to generate control signals for the inverter  70 . More particularly, the inverter  70  is controlled by pulse width modulated (PWM) control signals generated by controller  200  to output the desired AC waveform. When the generation facility is online, the controller  200  performs feedback current control by utilizing feedback current supplied by a current sensor located at an output side the inverter  70 . When the generation facility is offline, however, the control exercised by the controller  200  changes. Specifically, the controller  200  performs feedforward voltage control by utilizing feedforward voltage supplied by a voltage sensor located at an input side of the inverter  70 . These current and voltage sensors for feedback current control and feedforward voltage control, respectively may be part of the inverter  70  or separate therefrom as shown in FIG.  3 . 
     The controller  200  also outputs a disconnect control signal to contactor K 1  to control the connection of the generation facility to the utility grid  99 . Further details of the control method implemented by controller  200  are described below. 
     FIG. 4 illustrates the details of a line power unit  100  according to the invention. This line power unit (LPU)  100  includes an LPU controller  200  that may be programmed according to the techniques disclosed herein. FIG. 4 is a particularly advantageous embodiment of a line power unit  100  that may be controlled according to the invention. 
     FIG. 4 shows the details of the inventive line power unit  100  and its connections to the permanent magnet generator  15 , engine control unit  12  and utility grid  99 . The starter unit  220  is generally comprised of start inverter  80 , precharge circuit  78 , transformer  76 , and transformer  82 . The utility interface generally includes the main inverter  70 , low pass filter  72 , transformer  74 , voltage sensor  98 , and contactor K 1 . The LPU controller  200  generally includes phase and sequence detector circuit  97 , transformer  82 , full wave rectifier  83   b , full wave rectifier  83   a , control power supply  84  and LPU controller  200 . Correspondence between the general construction shown in FIG.  1  and the detailed embodiment shown in FIG. 4 is not important. This description is merely for the purpose of orienting one of ordinary skill to the inventive system. 
     Turning to the details of the line power unit  100  construction, the permanent magnet generator  15  has all three phases connected to PMG rectifier  60 . A DC bus  61  interconnects PMG rectifier  60  and main inverter  70 . A capacitor  62  is connected across the DC bus  61 . 
     The output of the main inverter  70  is connected to transformer  74  via low pass LC filter  72 . A voltage sense circuit  98  is connected to the output of the transformer  74  and supplies sensed voltages to the LPU controller  200  utilizing the data line shown. The voltage sense circuit  98  does not interrupt the power lines as may be incorrectly implied in the drawings. Instead, the voltage sense circuit is connected across the lines between transformer  74  and contactor K 1 . 
     A contactor K 1  is controlled by LPU controller  200  via a control line as shown in FIG.  4  and provides a switchable connection between transformer  75  and the utility grid  99 . A neutral line may be tapped from transformer  74  as further shown in FIG.  2  and connected to the grid  99 . 
     A separate start inverter  80  is connected to the DC bus  61  and the external DC voltage supply which may be constructed with a battery. The start inverter  80  is also connected to the permanent magnet generator  15 . 
     A precharge circuit  78  is connected to the grid via transformer  76  and transformer  82 . Precharge circuit  78  is further connected to the DC bus  61 . The precharge circuit  78  has a control input connected to a control data line that terminates at the LPU controller  200  as shown. 
     The line power unit  100  also supplies power to a local grid (e.g., 240 VAC three phase supplying auxiliary of local loads) via transformer  74 . This local grid feeds local loads and the turbine unit including pumps and fans in the turbine unit. 
     An auxiliary transformer  77  is also connected to the output of the transformer  74 . The output of the auxiliary transformer  77  is fed to full wave rectifier  83  to supply full wave rectified power to the control power supply  84 . The control power supply  84  supplies power to the engine control unit  12  and the LPU controller  200  as well as the I/O controller  310 . 
     The I/O controller  310  is connected via data lines to the LPU controller  200 . The I/O controller  310  is further connected to the engine control unit  12 , display unit  250 , and LPU external interface  320 . The LPU external interface  320  has a connection for communication and control via port  321 . 
     The LPU controller  200  has control lines connected to the start inverter  80 , main inverter  70 , precharge circuit  78 , transformer  82 , and contactor K 1 . Furthermore, data is also provided to the LPU controller  200  from control/data lines from these same elements as well as the phase and sequence detector  97  that is connected at the output of contactor K 1 . The LPU controller  200  also communicates data and control signals to the engine control unit  12 . 
     The engine control unit is supplied power from the control power supply  84  and communicates with engine sensors as shown. 
     State Machine Mode Control 
     FIG.  5 ( a ) is a state diagram showing the control states and permitted control state transitions. The state diagram shown in FIG.  5 ( a ) describes a state machine that may be implemented with the LPU controller  200  to control the line power unit  100  with the defined states and control state transitions. This state machine provides mode control for the following modes of operation: initialization, neutral, pre-charge, turbine start, power on-line, power off-line, and shut down. 
     The state diagram shown in FIG.  5 ( a ) assumes that the line power unit  100  is mounted in an equipment cabinet having cooling fans and pumps circulating cooling fluid through cold plates. A cold plate is merely a device that includes a plenum through which cooling fluid is circulated and to which various power conversion devices such as the main inverter  70  and start inverter  80  are mounted. The cold plate acts as a heat sink for these devices and thereby prevents overheating. The alternative shown in FIG.  5 ( b ) assumes that no such cabinet or cooling system is present and represents a simplified control state diagram for the invention. 
     Before describing the state transitions, a description of each control state will first be provided. 
     The power on/reset condition  500  is not really a control state but, rather, an initial condition that triggers the state machine. This initial condition includes power on of the line power unit  100  or reset of the line power unit  100 . 
     The initialization state  505  occurs after reset or power on and initializes global variables, initializes the serial communication ports including the I/O controller  310  and LPU external interface  320  having serial ports contained therein, executes a built-in-test (BIT), and initializes the real-time interrupt facility and input capture interrupt within the LPU controller  200 . 
     The initialization state also starts the line synchronization techniques of the invention which are further described below as well as starting the power factor control method of the invention. 
     The neutral state  510  monitors commands from the I/O controller  310  and engine control unit  12  to determine the next mode of operation as well as checking critical system parameters. 
     The pre-charge state  515  enables the pre-charge unit  78  to charge the DC link as well as checking on the rate of charging to determine correct hardware function. The pre-charge state  515  also performs diagnostic checks of the main inverter  70  to identify open or short type failures. 
     The neutral with pre-charge complete state  520  closes contactor K 1  and performs diagnostic tests of the line power unit  100 . 
     The purge cabinet state  525  purges the equipment cabinet in which the line power unit  100  is mounted including turning on any cooling fans and pumps and thereby bring the line power unit  100  into a purged and ready state. 
     The neutral with purge complete state  530  is an idle state that waits for an engine start command from the operator that is routed via port  321  to LPU external interface  320  to I/O controller  310  and thereby to LPU controller  200 . 
     The start engine state  535  generally performs the function of starting the engine that drives the permanent magnet generator  15 . 
     The start engine state  535  resets the start inverter  80  and performs basic diagnostic checks of the line power unit  100 . The start engine state  535  also verifies the DC link voltage and thereafter sets the pulse width modulated control signal supplied to the start inverter  80  to control the maximum speed that the start inverter  80  will drive the permanent magnet generator  15  as a motor to thereby permit the engine to start. 
     More particularly, the start engine state enables the start inverter  80 , receives updated speed commands from the engine control unit  12 , monitors fault signals from the start inverter  80 , and checks the speed of the engine and DC current drawn from the start inverter  80  to determine a successful start. 
     Actual starting of the engine is under the control of the engine control unit  12  which feeds fuel and any necessary ignition signals to the engine that is being spun by the permanent magnet generator  15 . The start engine state  535  then waits for a signal from the engine control unit  12  to terminate the start operation which involves sending a stop signal to the start inverter  80 . 
     Further details of engine starting can be found in related application Attorney Docket #1215-380P which is hereby incorporated by reference. 
     The neutral with start complete state  540  is an idle state wherein the engine is started and the permanent magnet generator  15  is being driven by the engine thereby producing three-phase power that is rectified by PMG rectifier  60  to supply DC bus  61  with DC power. The neutral with start complete state essentially waits for a power level command from the operator that is routed via port  321 , LPU external interface  320 , I/O controller  310  to the LPU controller  200 . 
     The power on-line state  545  enables the main inverter  70  in a current mode and sends pulse width modulated control signals to the main inverter  70  to output three-phase electrical power having the commanded power level. The power on-line state also performs various system checks to maintain safe operation such as verifying the DC link voltage and cold plate temperatures. 
     The open contactor state  550  opens the main contactor K 1 . 
     The power off-line state  555  switches the main inverter  70  to a voltage mode and sets the power level command to a nominal level to power the local loads. The power off-line state may perform various system checks to maintain safe operation. 
     The shut down state  560  disables the main inverter  70  and reinitializes global variables that are utilized by the state machine to control the line power unit  100 . 
     The purge cabinet state  565  performs essentially the same functions as the purge cabinet state  525  and ensures that the equipment cabinet housing the line power unit  100  cools down. 
     The open contactor state  570  waits for a nominal cool down period such as 5 minutes as well as controlling the contactor K 1  such that it breaks the connection with the grid  99  thereby ensuring disconnection from the grid  99 . 
     The clear faults state  575  clears any fault codes that may have triggered the shutdown. 
     The emergency stop indication  580  is not actually a control state, but instead illustrates the receipt of an emergency stop signal. The equipment cabinet housing the line power unit  100  preferably includes an emergency stop button that a user may trigger to shut down the system in an emergency. 
     The open contactor state  585  is triggered by the receipt of an emergency stop signal and opens main contactor K 1  thereby breaking the connection to the grid  99 . 
     The state transitions are represented in the drawings with arrows. These arrows convey important information. For example an unidirectional arrow such as → indicates a one-direction only permissible state transition. A bi-directional arrow, on the other hand, such as ←→ indicates bi-directional permissible state transitions. This may also be expressed by using the following bi-directional and unidirectional permissible state transition symbologies: (1) neutral state ←→ pre-charge state and (2) power on-line state → power off-line state. 
     The operation of the state machine illustrated in  5 ( a ) will now be described. 
     After receiving the power on or reset signal  500 , the initialization state  505  is triggered. After completion of the initialization procedures and successful built-in tests, the state machine permits the transition to neutral state  510 . 
     The neutral state  510  monitors commands from the operator and engine control unit  12 . Upon receiving an appropriate command, the state machine permits the transition to the pre-charge state  515  from the neutral state  510 . 
     As described above, the pre-charge state  515  triggers the pre-charge unit  78  to pre-charge the DC bus  61  to a desired pre-charge voltage. The pre-charge state  515  determines successful pre-charge by monitoring the pre-charge rate and determining whether the pre-charge voltage is within acceptable limits at the end of the pre-charge cycle. 
     If the pre-charge state  515  determines that the pre-charge cycle is not successful, then the state machine transitions back to the neutral state  510  as indicated by the fail path illustrated on FIG.  5 ( a ). Upon successful completion of the pre-charge cycle, however, the state machine permits the transition from the pre-charge state  515  to the neutral with pre-charge complete state  520 . 
     The neutral with pre-charge complete state  520  closes the main contactor K 1  thereby connecting the line power unit  100  to the grid  99 . Thereafter, the state machine permits the transition to the purge cabinet state  525 . 
     Upon successful purging of the cabinet and passing of any diagnostic tests such as checking the cold plate temperatures, the state machine permits the transition from the purge cabinet state  525  to the neutral with purge complete state  530 . Upon receipt of a start engine command, the state machine permits the transition to the start engine state  535 . 
     As described above, the start engine state  535  control the start inverter  80  to drive the permanent magnet generator  15  as a motor to spin the engine at a speed to permit the engine to be started. If the engine fails to start, then the state machine transitions to the neutral with purge complete state  530 . If the engine successfully starts, then the state machine transitions to the neutral with start complete state  540  which waits for the receipt of a power level command from the operator or a remote host. 
     Upon receipt of a non-zero power level command, the state machine transitions from the neutral with start complete state  540  to the power on-line state  545 . 
     If there is a utility outage, then the state machine transitions to the open contactor state  550  as further described in the utility outage ride-through section below. 
     On the other hand, receipt of a zero power level command transitions the state machine from the power on-line state to the neutral with start complete state  540 . 
     After the open contactor state  550  completes the operation of opening contactor K 1 , the power off-line state  555  is entered. Upon completion of the power off-line procedures in power off-line state  555 , the state machine transitions to the neutral with start complete state  540 . If a shutdown command is received, the state machine then transitions to the shutdown state  560 . The shutdown state  560  is followed by the purge cabinet state  565 , open contactor state  570  and clear faults state  575  and then the neutral state  510  thereby bringing the line power unit  100  into a neutral state. 
     Upon receipt of an emergency stop signal  580 , the open contactor state  585  is triggered. Thereafter, the shutdown state  560  is entered by the state machine and then the purge cabinet state  565 , open contactor state  570 , clear faults state  575  and neutral state  510  are sequentially entered by the state machine. 
     FIG.  5 ( b ) is a simplified state diagram that simplifies the states and state transitions illustrated in FIG.  5 ( a ). FIG.  5 ( b ) generally assumes that there is no cabinet that needs to be purged. The state machine in FIG.  5 ( b ) also consolidates some of the states illustrated in FIG.  5 ( a ). States having the same reference numerals are identical to those shown in FIG.  5 ( a ). The differences are pointed out below. 
     The neutral with pre-charge complete state  527  shown in FIG.  5 ( b ) differs from the neutral width pre-charge complete state  520  shown in FIG.  5 ( a ) essentially because the purged cabinet state  525  has been eliminated in FIG.  5 ( b ). The neutral with pre-charge complete state  527  closes the main contactor K 1  and awaits for receipt of a start engine command from an operator or other device such as a remote host. 
     Further details of such remote host that may be utilized with this invention are provided by related application Ser. No. 09/140,392, presently U.S. Pat. No. 6,055,163, the contents of which are hereby incorporated by reference. 
     The power off-line state  556  shown in FIG.  5 ( b ) also differs from the power off-line state  555  shown in FIG.  5 ( a ). Essentially, the power off-line state  556  combines the open contactor state  550  with the power off-line state  555  shown in FIG.  5 ( a ). Thus, the power off-line state  556  performs the functions of opening the contactor K 1 , switching the main inverter  70  to a voltage mode and setting the power level to a nominal level to power the local loads. Furthermore, various system checks may be performed to maintain safe operation. 
     The operation of the state machine shown in FIG.  5 ( b ) is essentially the same as that shown in FIG.  5 ( a ) with differences noted below. 
     The main difference is the consolidation of the neutral with pre-charge complete state  520  and the neutral with purge complete state  530  and the elimination of the purged cabinet state  525  from FIG.  5 ( a ). Thus, when the pre-charge state  515  successfully completes the pre-charge cycle, the neutral with pre-charge state  527  is entered by the state machine. 
     Upon receipt of an engine start command, the start engine state  535  is entered by the state machine. Furthermore, upon a utility outage, the state machine transitions directly from the power on-line state  545  to the power off-line state  556  as shown in FIG.  5 ( b ). 
     By utilizing the state machines of either FIGS.  5 ( a ) or  5 ( b ), the invention provides a real-time control method for controlling the line power unit  100 . This real-time control unit includes specifically defined control states that ensure correct and safe operation of the line power unit  100 . Furthermore, various system checks and diagnostics are performed throughout which further ensure safe operation and which further affect state transitions. 
     Line Synchronization 
     FIG.  6 ( a ) illustrates the frequency sensing component of the frequency synthesizing apparatus and method according to the invention in relation to other components of the line power unit  100  and the utility grid  99 . 
     The phase and sequence detecting circuit  97  shown in FIG. 4 may have the construction shown in FIG.  6 ( a ). More particularly, the sequence detector includes a transformer  605  connected to two phases A, B of the utility grid  99 . In this way, transformer  605  inputs the voltage and frequency of the utility grid  99 . 
     This sensed voltage from transformer  605  is supplied to a low pass filter  610  and then to an optical isolator  615 . The output of the optical isolator  615  is a uni-polar square wave as shown in FIG.  6 ( a ) that is supplied to the line power unit controller  200 . Specifically, the line power unit controller includes a vector control board  210  having an A/D converter  215  that accepts the uni-polar square wave from the optical isolator  615 . 
     The A/D converter preferably converts this uni-polar square wave into a 10-byte digital signal that is fed to the digital signal processor (DSP)  220 . The output of the DSP  220  is fed to a pulse width modulation (PWM) signal generation device  225 . 
     The pulse width modulation signals from PWM  225  are fed to gate drive circuit  230  which drives the IGBT switches  71  located within the main inverter  70 . The main inverter  70  is fed a DC voltage from DC bus  61  as shown in FIG.  4 . For simplicity, this connection is not shown in FIG.  6 ( a ).  9   
     The output of the main inverter  70  is filtered by inductor  72 . Then, the voltage is stepped up by transformer  74  and supplied to the utility grid via contactor K 1 . The output of the transformer  74  also supplies local loads as shown in FIG. 6 a.    
     The frequency synchronization apparatus shown in FIG.  6 ( a ) operates in the following general manner. The output of the optical isolator  615  is a uni-polar square wave with a voltage swing preferably within the limits of the A/D converter  215 . The DSP  220  controls the A/D converter  215  by initiating the conversion and reading of the digital value at a fixed frequency. This fixed frequency establishes the time base for which the inventive methods can compute the actual frequency of the signal and thereby the actual frequency of the utility grid  99 . This is accomplished by determining when the falling edge of the signal occurred and counting the number of samples between successive falling edges. 
     Alternatively, the invention could utilize the rising edge of the signal, but for simplicity this explanation will focus on the falling edge implementation. 
     FIGS.  6 ( b )-( d ) illustrate various signals utilized by the invention to perform synchronization. FIG.  6 ( b ) illustrates the SYNC signal that is the fixed frequency signal utilized by the DSP  220  to control the initiation and reading of the data from the A/D converter  215 . FIG.  6 ( c ) illustrates the THETA signal which is a variable in software that is utilized to represent the angle of the utility sine wave and ranges from 0° to 360° in a series of stepped ramps each of which runs from 0° at the falling edge of the SYNC pulse to 360° at the next falling edge of the SYNC pulse. FIG.  6 ( d ) illustrates THETA˜ which is the phase shift added to THETA for power factor control as further described below. 
     The synchronization method is further illustrated in FIG.  7 ( a )-( b ). As shown in FIG.  7 ( a ), the synchronization function is started or called every 64 microseconds at which time step  702  causes the digital signal processor  220  to read the A/D  215  input. As further illustrated in FIG.  7 ( a ), the input signal is a square wave at the frequency of the grid. 
     Then, step  704  sets the minimum, maximum and typical constants which are set according to the selected grid frequency. The grid frequency is chosen between either 50 or 60 hertz which thereby effects the values for the minimum, maximum and typical constants in step  704 . 
     Thereafter, step  706  increments the frequency counter which is represented as FreqCount=FreqCount+1. The variable FreqCount is the number of times this routine is called between falling edges of the input signal. 
     After step  706 , then step  708  checks whether the FreqCount variable is out of range. If so, the Count variable is set to a typical value in step  710  and the step  712  then clears the status flag that would otherwise indicate that the line power unit  100  is in synchronization with the grid  99 . In other words, step  712  clears this status flag thereby indicating that the line power unit is not in synchronization with the grid  99 . 
     After step  712  or if decision step  708  determines that the FreqCount is not out of range, then step  714  then determines whether there is an input from the falling edge detector. Step  714  determines whether the falling edge of the synchronization pulse has occurred. If yes, then the flow proceeds to jump point A which is further illustrated in FIG.  7 ( b ). 
     Step  708  essentially determines whether the grid  99  is present or whether there is a utility outage. If there is utility outage, then the FreqCount variable will exceed the maximum thereby causing the system to set the count value to a typical value in step  710 . 
     FIG.  7 ( b ) continues the frequency synchronization process beginning with a determination of whether the frequency of the incoming signal, input is within the correct range. Particularly, step  716  determines whether the FreqCount variable is within the minimum and maximum values. If not, then step  722  sets the count variable to a typical value and then step  724  sets a status flag indicating synchronization error. 
     On the other hand, if the FreqCount variable is within the correct range as determined by step  716 , then step  718  sets the Count variable equal to 360°/FreqCount. Then step  720  clears the status flag indicating no synchronization error. 
     After either steps  720  or  724 , the method executes step  726  which resets the FreqCount variable to 0. 
     Thereafter, the method then determines whether THETA is in synchronization with the incoming signal input. THETA should equal 0 at the same time the falling edge of the input signal is detected if synchronization has occurred. This is determined by step  728  which checks whether THETA is substantially equal to 360° or 0°. If not, the status flag is cleared by step  732  indicating that the line power unit is not in synchronization. If yes, then step  730  sets the status flag indicating that the LPU  100  is in synchronization with grid  99 . 
     After setting the status flags in step  730  or step  732  then the process adjusts THETA to maintain or achieve synchronization with the input signal. Particularly, step  734  first determines if THETA is less than 180°. If yes, then the error variable is set to minus THETA. If not, then step  738  sets the error variable equal to 360°−THETA. 
     After setting the error variable in step  736  or step  738 , then the method proceeds to limit the rate of change of the Error variable. The preferred embodiment shown in FIG. 7 b  limits the Error variable to +/−0.7° in step  740 . Thereafter, step  742  sets the THETA variable equal to THETA plus the Error variable. 
     After step  742 , the flow returns via jump point B to the flow shown in FIG.  7 ( a ) beginning with step  744 . 
     As further shown in FIG.  7 ( a ), the process proceeds after jump point B by generating THETA by incrementing THETA by the count variable every 64 microseconds. This process generates the THETA signal shown in FIG.  6 ( c ). More particularly, step  744  sets THETA=THETA+Count thereby incrementing THETA. 
     After step  744 , decision step  746  determines whether THETA is greater than 360°. If yes, step  748  resets THETA to THETA minus 360° to bring THETA within range. 
     If not, then step  750  determines the phase shift variable THETA˜ by setting THETA˜ equal to THETA plus any desired phase shift. 
     THETA˜ is an optional variable as is step  750 . This optional step  750  permits an operator to adjust the power factor of the three phase power delivered to the grid  99  by utilizing the phase shift variable. In essence, the operator merely needs to input data to set the phase shift variable to thereby adjust the power factor. Step  750  can then adjust the power factor by setting THETA˜=THETA+phase shift. 
     After step  750 , the synchronization function has completed its operations as indicated by end of SYNC function step  752 . This routine is again called after 64 microseconds have elapsed since the initiation of the SYNC function in step  700 . 
     The inventive methodology illustrated in FIGS.  7 ( a ) and  7 ( b ) outputs a THETA˜ that is utilized by a known vector algorithm in the vector board  210  to generate pulse width modulation signals from PWM  225  that are fed to gate drive  230  to thereby control the main inverter  70 . Such pulse width modulation control of the power can then shift the phase of the power output from main inverter  70  and thereby bring the output power into synchronization with the utility grid  99 . 
     Instead of sampling the grid frequency, circuit  97  may also synthesize a grid frequency. This is necessary when the line power unit  100  is operating in a stand-alone mode or when the utility grid  99  is not available. Thus, the system must synthesize a frequency when the grid is temporarily disconnected so that the output power frequency is self-regulating. 
     One of the advantages of the inventive line synchronization technique is that it limits the resynchronization rate in step  740 . By limiting the resynchronization rate, the invention provides a smooth transition from out-of-SYNC line power unit  100  to an in-SYNC line power unit  100  that is in synchronization with the utility grid  99 . This reduces transient voltages, stress on the components and increases safety. 
     As further described above, this line synchronization technique also permits power factor control such that an operator or remote host can input a phase shift data via port  321  and thereby control the power factor of power supplied to the grid  99 . 
     Utility Outage Ride-through 
     The state machines described in FIGS.  5 ( a )-( b ) include states that are involved in the utility outage ride-through methodology. Specifically, the neutral with start complete state  540 , power on-line state  545 , open contactor state  550 , and power off-line state  555  shown in FIG.  5 ( a ) are the control states involved in the utility outage ride-through methodology. 
     Alternatively, the neutral with start complete state  540 , power on-line state  545  and power off-line state  556  shown in FIG. 5 b  are alternative control states that may also be utilized by the utility outage ride-through methodology of this invention. 
     The utility outage ride-through methodology may be implemented within a controller such as the controller  200  shown in FIG. 3 or the LPU controller  200  shown in FIG.  4 . 
     The utility outage ride-through method that may be programmed into the LPU controller  200  is shown in FIG.  8 . Furthermore, the utility outage ride-through methodology shown in FIG. 8 may be utilized by the state machine shown in FIGS. 5 a-b  to control the state transitions mentioned above. 
     The utility outage ride-through method shown in FIG. 8 begins with step  800 . Then, steps  805 ,  810 ,  815 ,  820 ,  825  determine the existence of a fault condition. Upon the occurrence of any of these fault conditions, then the flow proceeds to open main contactor step  830 . 
     More particularly, step  805  determines whether there is a loss of utility authorization. In general, most electric utilities send authorization data to each electrical power generator supplying power to the grid  99 . In this way, the utility can either authorize or cancel authorization for connection to the grid  99 . Step  805  determines whether the utility authorization has been cancelled. 
     Step  810  determines whether there is a loss of phase. This may be performed by sampling the input from the phase and sequence detector  97 . If any of the phases have been lost, then step  810  directs the flow to open main contactor step  830 . 
     Similarly, loss of synchronization step  810  determines whether there is a loss of synchronization between the line power unit  100  and the grid  99 . This loss of synchronization may be determined from the status flag “LPU in SYNC” set by the synchronization method described above in relation to FIGS.  7 ( a )-( b ). 
     Step  820  decides whether the industrial turbo generator (ITG) host has sent an off-line command via port  321  to the LPU controller. It is not essential that an ITG host be utilized, and this step  820  may be simplified to receive any off-line command by LPU controller  200 . 
     Step  825  determines whether the AC voltage of the grid  99  is out of range. The voltage sense circuit  98  senses this AC grid  99  voltage and sends a signal to the LPU controller  200  which can thereby determine whether the VAC is out of range in step  825 . 
     If any fault condition has occurred, then step  830  is executed which opens the main contactor K 1  and disconnects the line power unit  100  from the grid  99 . 
     Thereafter, step  835  resets or clears a time counter which is preferably a 30 second time counter. 
     Then, step  840  sets the operational mode to offline which causes the state machine of FIG.  5 ( a ) to transition from the open contactor state  550  to the power off-line state  555 . The power on-line state  545  to open contactor state  550  transition occurs in step  830  and is triggered by any of the fault conditions described above. 
     Thereafter, off-line voltage control is initiated by step  845  wherein the main inverter  70  is controlled by LPU controller  200  in a voltage control mode for stand-alone operation and feeding of the local loads. 
     After setting the off-line voltage control in step  845 , step  850  enables the main inverter  70  to thereby supply power to the local loads. This ends the flow as indicated by step  895 . 
     The system then continues checking the occurrence of fault conditions as described above. Continued fault conditions have the effect of clearing the 30 second counter each time. 
     When all of the faults have been cleared, then the flow proceeds to step  855  which determines whether the on-line or off-line mode (state) is being utilized by the line power unit  100 . Continuing with this example, the off-line mode is now utilized by the state machine. Thus, the mode determination step  855  directs the flow to step  860  which begins incrementing the 30 second counter. 
     If the counter has not yet reached the 30 second time limit, then step  865  directs the flow to off-line voltage control setting step  845  and enable three phase inverter step  850  the effect of which is to return or loop back to the increment 30 second counter step  860 . 
     This loop continues until the 30 second counter has elapsed as determined by step  865 . Thereafter, step  870  disables the main inverter  70 . After disabling the main inverter  70 , step  875  closes main contactor K 1  thereby connecting the line power unit  100  to the grid  99 . Then, the mode is set to the online mode which transitions the state machine from the neutral with start complete state  540  to the power on-line state  545 . This also causes the next loop to take the left branch as determined by the mode determination step  855  which will now sense the online mode. 
     If the mode is on-line, the flow proceeds from step  855  to on-line current control step  885  which controls the main inverter  70  in a current control mode. Thereafter, step  890  enables the inverter  70  to thereby supply power to the grid  99  via closed contactor K 1 . The process is then completed as indicated by end step  895 . 
     By utilizing the utility outage ride-through methodology above, the invention has the capability of detecting a utility outage or other fault condition thereby triggering disconnection from the grid. The invention also provides a smooth transition from a current mode (utility connected) to a voltage mode (utility outage) for the main inverter  70 . 
     The benefit is more stability and faster response to wide swings in generator voltage. The invention also has the feature of over-current limiting which is a self-protection function which prevents voltage brown-out at excessive current levels. This method also easily transitions from voltage mode to current mode when reconnecting to the grid thereby minimizing transients on power output to the grid  99 . 
     When the line power unit  100  disconnects from the grid  99 , a typical system will vary greatly in speed and output voltage as it is rapidly unloaded. To prevent such large voltage swings from reaching the inverter  70  output, a feed forward technique is utilized as described above to control the inverter  70  output voltage. 
     Using such feed forward control, the generator voltage is sampled and used to establish the modulation index of the pulse-width modulated sinusoidal voltage produced by the inverter  70  keeping the sinusoidal output voltage nearly constant. This control technique provides the high level of stability and fast response needed for rapid changes of input voltage. Over-current protection is provided by reducing the modulation index when the maximum allowed output current is reached, producing a brown-out effect. 
     When the grid power is restored, the line power unit  100  voltage is first synchronized with the grid voltage. After synchronizing with the grid (as determined by step  815  and implemented by the synchronization techniques described above), normal current controlled power flow into the grid  99  can then resume. 
     Power Factor Control 
     The system may be further enhanced by providing an apparatus and method for controlling the power factor of power delivered to the grid  99 . Although the synchronization control described above also provides power factor control, the invention also provides an alternative control loop that controls the power factor. 
     The power factor control device and methods according to the invention may be applied to a wide variety of grid-connected generation facilities as graphically illustrated by FIG.  2 . The current controlled inverter  70  may be controlled with the device shown in FIG.  9 . 
     FIG. 9 illustrates a device for controlling power factor that interfaces with a current controlled inverter  70  as shown in FIG. 9 or, alternatively, the current controlled inverter  70  shown in FIG. 2 or  4 . 
     This power factor control device includes a sensor  98  that senses the current supplied to the utility  99  from the inverter  70 . All three phases (I a , I b , I c ) of the current supplied to the utility  99  are sensed by sensor  98  and supplied to three-phase to two-phase transformer  905  to output two-phase D-Q coordinate signals I d , I q . 
     The two-phase signals I d , I q  are then supplied to a stationary-to-rotating reference frame transformation unit  910  that changes the two-phase AC signals (I d , I q ) from the stationary to a synchronously rotating reference frame which converts the signals from AC to DC. 
     The DC signals are then compared against reference signals I q Ref , I d Ref  by comparators  920  and  925 , respectively. The comparators  920 ,  925  are preferably proportional-plus-integral gain stages that perform proportional-plus-integral comparison operations between the reference signals I q Ref , I d Ref  and the DC signals I d , I q . 
     The reference signals I q Ref , I d Ref  may be supplied by the LPU controller  200  which, in turn, may be supplied these reference signals from an operator via port  321 , LPU external interface  320 , I/O controller  310 . In this way, either the LPU controller  200  or the operator can command the power factor. 
     Furthermore, the utility may also request a certain power factor to be supplied to the grid  99  by the line power unit  100 . Such a request can be fed to the system via the reference signals I q Ref , I d Ref . 
     The proportional plus integral gain stages  920 ,  925  output voltage signals V q , V d  that are transformed back to a stationary reference frame by rotating to stationary reference frame transforming unit  930  to output AC voltages V q , V d . These AC voltages are then subjected to a two-phase to three-phase transform by unit  935  to thereby output three-phase voltages V a , V b , V c  which are then sent to a pulse width modulator which controls the switches in a three-phase, full-wave IGBT bridge within the inverter  70  to produce AC currents (I a , I b , I c ) with a vector that contains the real and reactive components commanded by I d Ref  and I q Ref . This power factor control loop provides independent control of the real and reactive components of the current output to utility  99 . This invention draws upon widely known vector control techniques developed for induction motor drives. The desired amplitudes of real and reactive current supplied to the utility  99  are commanded by I q ref  and I d ref , respectively. The control loop described above drives the output current to the utility (I a , I b , I c ) so that the magnitude and phase contain the commanded real and reactive current components. 
     This is often beneficial in improving the power factor in the utility distribution system  99 . Furthermore, the utility interface  99  may also be a local grid. Such a local grid may also require power factor correction due to large inductive or capacitive loads on the local grid. The poor power factor that such large inductive or capacitive loads cause may be corrected by utilizing the power factor control method and apparatus disclosed herein. 
     The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.

Technology Classification (CPC): 7