Patent Description:
The use of electrical generators to provide electrical power to components is known. One example use of an electrical generator is on a job site where line power (also known as utility power) may not be present or where the electrical generator is used in place of line power/utility power. In some instances, different components at a job site may require different types of electrical power, in which case separate electrical generators may be used to power the different components. Document <CIT> discloses a decentralized energy network system. Document <CIT> discloses a dual fuel system and method of supplying power to loads of a drilling rig. Document <CIT> discloses an electric generator having multiple receptacles.

An electrical generator and associated methods are described herein where the electrical generator is configured to simultaneously output different types of electrical power so that electrically powered components that require different types of electrical power can be simultaneously powered by the electrical generator. The electrical generator can be used at any location where electrically powered components that require different types of electrical power are utilized. In addition to outputting different types of electrical power, the electrical generator is also configured to output at least one type of electrical power as well as a thermal control fluid that can include, but is not limited to, a liquid, gas, or mixture thereof for use in thermal control (heating and/or cooling) of an external component.

In one embodiment, the electrical generator is configured to generate and output a modulated electrical power that is output at a modulated electrical power output (which may also be referred to as a variable frequency and/or variable amplitude power output), as well as configured to generate and output an export (or standard) electrical power that is output at an export electrical power output (which may also be referred to as a synchronous electrical power output). An electrically powered component that requires modulated electrical power can be powered from the modulated electrical power output. An electrically powered component that requires export/standard/synchronous electrical power may also be simultaneously powered from the export electrical power output.

According to the invention, the electrical generator is provided with a thermal control system and can output a thermal control fluid, which can be a liquid, gas, or mixture thereof, for thermal control of a component at the job site. For example, the thermal control fluid can be a cooling fluid used to cool one of the electrically powered components receiving electrical power from the electrical generator. In another embodiment, the thermal control fluid can be used to cool or heat an electrical component that is not electrically powered by the electrical generator. After exchanging heat with the component, the thermal control fluid can be pumped back to the electrical generator for heat exchange before being returned back to the component for additional thermal control. In one embodiment, the heat exchange of the thermal control fluid can occur entirely within the electrical generator via a heat exchanger that is internal to the electrical generator. In another embodiment, the thermal control fluid can be directed into a heat exchanger that is external to the electrical generator but fluidly connected to the electrical generator to receive the thermal control fluid for heat exchange before the thermal control fluid is directed back into the electrical generator. In still another embodiment, the thermal control fluid can be directed through both an internal heat exchanger and an external heat exchanger.

In another embodiment, a plurality of user interface modules can be provided where each user interface module can be individually removably installed on the electrical generator to control operation of the electrical generator. In one embodiment, each user interface module can be associated with a particular electrically powered component to be powered by the modulated electrical power to appropriately control the modulated electrical power at the modulated electrical power output based on the particular electrically powered component connected to the modulated electrical power output. In another embodiment, each user interface module can be associated with a particular electrically powered component to be powered by the export electrical power to appropriately control the export electrical power at the export electrical power output based on the particular electrically powered component connected to the export electrical power output. The user interface modules can be changed out based on the electrically powered component connected to (or to be connected to) the modulated electrical power output and/or to the export electrical power output.

In one embodiment described herein, an electrical generator can include an engine having a mechanical output, a first electrical power output that outputs a first type of electrical power, and a second electrical power output that outputs a second type of electrical power, where the second type of electrical power differs from the first type of electrical power. Conversion components are connected to the mechanical output and to the first and second electrical power outputs, where the conversion components are configured to convert the mechanical output into the first type of electrical power and the second type of electrical power. The first type of electrical power output at the first electrical power output can be direct current electrical power, and the second type of electrical power output at the second electrical power output can be synchronous alternating current electrical power. Alternatively, the first type of electrical power output at the first electrical power output can be modulated alternating current electrical power, and the second type of electrical power output at the second electrical power output can be synchronous alternating current electrical power. In another embodiment, the first type of electrical power output at the first electrical power output can be direct current electrical power, and the second type of electrical power output at the second electrical power output can be modulated alternating current electrical power. In another embodiment, the electrical generator can have more than two electrical power outputs with any combination of modulated alternating current electrical power, synchronous alternating current electrical power, and direct current electrical power.

In another embodiment described herein, an electrical generator can include an engine having a mechanical output, conversion components connected to the mechanical output that are configured to convert the mechanical output into at least one alternating current that is output from at least one alternating current output, and a thermal control system that can output a thermal control fluid, which can be a liquid, gas or mixture thereof, from the electrical generator for cooling or heating an external component. The thermal control system can include a tank configured to contain a thermal control fluid, a pump connected to the tank, a heat exchanger connected to the pump, and a first flow path between the thermal control system and a thermal control fluid outlet connector that can be connected to in order to direct thermal control fluid to a component external to the electrical generator. In this embodiment, the electrical generator not only provides electrical power (for example modulated electrical power and/or export electrical power) but also provides a thermal control fluid for thermal control of a component that is external to the electrical generator.

In another embodiment described herein, a system can include an electrical generator as described herein, a first component of a horizontal directional drilling system connected to the first electrical power output of the electrical generator, and a second component of a horizontal directional drilling system connected to the second electrical power output of the electrical generator.

In another embodiment described herein, a system can include an electrical generator as described herein, and a plurality of user interface modules. Each user interface module is individually removably installable on the electrical generator to control operation of the electrical generator, and each user interface module is configured to control the electrical power that is output at the electrical power output whereby the electrical power differs for each user interface module.

In another embodiment described herein, a method can include connecting an electric drive motor of an implement/device including, but not limited to, a pit pump, to an electrical power output of an electrical generator controlled by a first user interface module. Thereafter, the first user interface module is removed and a second user interface module is installed that is configured to operate with a second electrically operated implement other than the electric drive motor of the first implement. The electric drive motor of the first implement is disconnected from the electrical power output of the electrical generator, and the second electrically operated implement is connected to the electrical power output of the electrical generator.

Referring to <FIG>, an electrical generator <NUM> as described in more detail below is illustrated. The electrical generator <NUM> is configured to simultaneously output different types of electrical power from at least two different electrical outputs <NUM>, <NUM>. The electrical output <NUM> may be considered a first electrical output or a second electrical output, while the electrical output <NUM> may be considered a second electrical output (if the electrical output <NUM> is considered the first) or a first electrical output (if the electrical output <NUM> is considered the second). Different electrically powered components <NUM>, <NUM> that require different types of electrical power can receive power from the outputs <NUM>, <NUM> so as to be simultaneously powered by the electrical generator <NUM>. In some embodiments, both of the components <NUM>, <NUM> need not be powered simultaneously. Instead, the electrical generator <NUM> can be used to power only the component <NUM> or only the component <NUM>. The different types of electrical power that can be output from the outputs <NUM>, <NUM> can include direct current electrical power and an alternating current electrical power, or different forms of alternating current electrical power such as modulated alternating current electrical power (which may also be referred to as a variable frequency and/or variable amplitude power output) and synchronous alternating current electrical power.

In one embodiment, the output <NUM> can be a direct current output that outputs a direct current (DC) electrical power that is then converted by a power converter externally of the electrical generator <NUM> into either a modulated, alternating current (AC) electrical power or a synchronous AC electrical power depending upon the electrical power requirements of the component <NUM>. In another embodiment, the output <NUM> can output a modulated AC electrical power or a synchronous AC electrical power required by the component <NUM> where the power converter and the conversion into the modulated or synchronous AC electrical power occurs internally of the electrical generator <NUM>. In another embodiment, the output <NUM> can output DC electrical power that is not converted to AC. In some embodiments, the output <NUM> may be referred to as a modulated electrical power output that outputs modulated electrical power (which may also be referred to as a variable frequency and/or variable amplitude power output).

Similarly, the output <NUM> can be a direct current output that outputs DC electrical power that is then converted by a power converter externally of the electrical generator <NUM> into either a modulated, alternating current (AC) electrical power or a synchronous AC electrical power depending upon the electrical power requirements of the component <NUM>. In another embodiment, the output <NUM> can output a modulated AC electrical power or a synchronous AC electrical power required by the component <NUM> where the power converter and the conversion into the modulated or synchronous AC electrical power occurs internally of the electrical generator <NUM>. In another embodiment, the output <NUM> can output DC electrical power that is not converted to AC. In some embodiments, the output <NUM> may be referred to as an export electrical power output that outputs an export (or standard or synchronous) AC electrical power required by the component <NUM>.

In some embodiments, the component <NUM> may be powered by the output <NUM> and the component <NUM> may be powered by the output <NUM>.

The component <NUM> may be electrically connected to the output <NUM> via a power line <NUM>, while the component <NUM> may be electrically connected to the output <NUM> via a power line <NUM>. In addition, a data line <NUM> can be provided between the component <NUM> and the electrical generator <NUM> to transmit various data between the electrical generator <NUM> and the component <NUM>, while a data line <NUM> can be provided between the component <NUM> and the electrical generator <NUM> to transmit various data between the electrical generator <NUM> and the component <NUM>. In addition, as discussed in further detail below, in some embodiments thermal control fluid supply and return lines 28a, 28b (depicted in dashed lines) can extend between the electrical generator <NUM> and the component <NUM> and/or thermal control fluid supply and return lines 30a, 30b (depicted in dashed lines) can extend between the electrical generator <NUM> and the component <NUM>.

In addition, one or more additional ones of the components <NUM> may be connected to one another in series as illustrated (or in parallel) with one or more power, data and/or thermal control fluid lines <NUM> connecting the components <NUM>. Similarly, one or more additional ones of the components <NUM> may be connected to one another in series as illustrated (or in parallel) with one or more power, data and/or thermal control fluid lines <NUM> connecting the components <NUM>.

The electrical generator <NUM> illustrated in <FIG> is useful in locations where different electrically powered components, such as the components <NUM>, <NUM>, are used that have different electrical power requirements. For example, the component <NUM> may be an electrically powered component or system that experiences variable loads. Examples of the components <NUM> that can be powered by the electrical generator <NUM> include, but are not limited to, an electric drive motor of a pit pump used at a horizontal directional drilling site, one or more electrically powered components of a horizontal directional drilling (HDD) rig, a drilling mud cleaning system used with the HDD rig, a tool truck, maintenance trailer, a light plant, a control cab, a building, a portable saw mill, a cement mixing plant, a welder, or a pipe flange facing machine.

The component <NUM> may be an electrically powered component that requires standard (or clean or synchronous) electrical power which may be referred to as export power. Examples of the components <NUM> that can be powered by the electrical generator <NUM> include, but are not limited to, the same components as the components <NUM> but configured to be run by synchronous power; a heater at an HDD site; an air compressor; and hand tools.

<FIG> illustrates one embodiment of an electrical system architecture of the electrical generator <NUM> that produces different electrical powers at the outputs <NUM>, <NUM>. In this embodiment, the output <NUM> outputs DC electrical power that is then converted externally of the electrical generator <NUM> into modulated AC electrical power, while the output <NUM> outputs synchronous AC electrical power. The electrical generator <NUM> includes a housing <NUM> (illustrated in dashed lines) that houses some of the elements described herein. In this example, the electrical generator <NUM> includes an engine <NUM>, such as a diesel engine, a gasoline powered engine, a propane powered engine, or the like, that outputs mechanical energy via an output shaft <NUM>. The engine <NUM> can be powered by any suitable engine fuel (wet/dry). Examples of suitable engine fuels that can be used include, but are not limited to, gasoline, diesel fuel, natural gas, propane, and the like.

In addition, conversion components are provided that convert the mechanical energy of the output shaft <NUM> into the different electrical powers at the outputs <NUM>, <NUM>. The conversion components can be any elements suitable for generating the different electrical powers at the outputs <NUM>, <NUM>. In the illustrated example, the conversion components include an electrical generating element <NUM>, a first power converter <NUM>, and a second power converter <NUM>.

The electrical generating element <NUM> can be any device that is suitable for converting the torque of the output shaft <NUM> into an AC output <NUM>, for example single phase or <NUM>-phase AC. In one non-limiting example, the electrical generating element <NUM> can be a permanent magnet motor that is mechanically connected to and driven by the output shaft <NUM>. The permanent magnet motor can be any permanent magnet motor that is suitable for converting the mechanical input of the shaft <NUM> into the AC output <NUM>.

The power converter <NUM> is configured to receive the AC output <NUM> and convert the AC to DC electrical power that is output along a DC output bus <NUM>. The power converter <NUM> can have any configuration that is suitable for converting the AC to DC.

In the illustrated example, the DC output bus <NUM> has at least two branches, with one branch directing DC electrical power to the power converter <NUM>. The power converter <NUM> converts the DC electrical power into the export, synchronous AC electrical power that is output at the electrical power output <NUM>. In one embodiment, the power converter <NUM> can be configured to generate <NUM>/<NUM> VAC single phase AC that is output from the output <NUM>. In another embodiment, the power converter <NUM> can generate <NUM> VAC <NUM>-phase AC that can be output from the output <NUM>. The power converter <NUM> can have any configuration that is suitable for converting DC electrical power into the synchronous AC electrical power. An example of the power converter <NUM> can be a DC to AC inverter.

The other branch of the DC output bus <NUM> directs the DC electrical power to the output <NUM>. In this embodiment, the electrical component <NUM> that is electrically connected to the output <NUM> includes a power converter <NUM> that is configured to convert the DC electrical power to modulated AC electrical power for use by the electrical component <NUM>. The power converter <NUM> can have any configuration that is suitable for converting DC electrical power to modulated AC electrical power.

<FIG> illustrates another embodiment of an electrical system architecture of the electrical generator <NUM> that can produce different electrical powers at electrical outputs thereof. Elements that are identical to elements in <FIG> are referenced using the same reference numerals. Like the embodiment in <FIG>, the embodiment in <FIG> can output DC electrical power at the output <NUM> that is then converted externally of the electrical generator <NUM> by the power converter <NUM> into modulated AC electrical power, while the output <NUM> outputs synchronous AC electrical power. Instead of or in addition to the output <NUM>, the embodiment in <FIG> can include an internal power converter <NUM>' that can be similar in function and construction to the power converter <NUM> and that converts the DC electrical power to modulated AC electrical power internally within the electrical generator <NUM> and then directs the modulated AC electrical power to an output <NUM>' for use by an external electrical component. Further, instead of or in addition to the output <NUM> and the output <NUM>', the embodiment in <FIG> can include an output <NUM> that outputs DC electrical power for use by an external electrical component requiring DC electrical power. Similarly, instead of or in addition to the output <NUM>, the embodiment in <FIG> can include an output <NUM>' that outputs DC electrical power that is then converted externally of the electrical generator <NUM> by an external power converter <NUM>' into synchronous AC electrical power for use by the external electrical component <NUM> requiring synchronous AC electrical power.

The embodiment of the electrical generator <NUM> in <FIG> can include any two or more of the outputs <NUM>, <NUM>', <NUM>, <NUM>, <NUM>' in any combination thereof. In one embodiment, the electrical generator <NUM> in <FIG> includes the output <NUM>' and the output <NUM>.

<FIG> illustrates another embodiment of an electrical system architecture of the electrical generator <NUM> that can produce different electrical powers at different electrical outputs thereof. Elements that are identical to elements in <FIG> and/or <NUM> are referenced using the same reference numerals, or the same reference numerals with the ending "-<NUM>" or "-<NUM>". Like the embodiments in <FIG> and <FIG>, the embodiment in <FIG> can output DC electrical power at the output <NUM> that is then converted externally of the electrical generator <NUM> by the power converter <NUM> into modulated AC electrical power. Alternatively, similar to the construction depicted in <FIG>, the electrical generator <NUM> in <FIG> can include an internal power converter <NUM>'. In addition, the electrical generator <NUM> in <FIG> can include two outputs <NUM>-<NUM>, <NUM>-<NUM> each of which outputs DC electrical power from the bus <NUM>. Each of the DC electrical powers is then converted by an external power converter <NUM>-<NUM>, <NUM>-<NUM>, respectively, into synchronous AC electrical power. The power converter <NUM>-<NUM> is configured for high power conversion, while the power converter <NUM>-<NUM> is configured for lower power conversion. High power conversion can include, but is not limited to, generating power of about <NUM> kW or more. Lower power conversion can include, but is not limited to, generating power of about <NUM> kW (or about <NUM> amps), or about <NUM> kW (or about <NUM> amps). The power from the power converter <NUM>-<NUM> can be used to power a device requiring synchronous AC electrical power including, but not limited to, a device with higher power requirements, for example up to about <NUM> kW or more. The power from the power converter <NUM>-<NUM> can be used to power a device requiring synchronous AC electrical power including, but not limited to, a device with lower power requirements, for example about <NUM> kW (or <NUM> amps) or about <NUM> kW (or about <NUM> amps).

In another embodiment, the electrical generator <NUM> can be connected to one or more alternative power sources that are external to the electrical generator <NUM>. The electrical generator <NUM> may receive electrical power from these alternative power sources and/or the electrical generator <NUM> may direct electrical power to these alternative power sources. In this embodiment, the electrical generator <NUM> may also be referred to as an energy handling system since the electrical generator <NUM> can handle electrical energy from and/or direct electrical power to multiple electrical power sources, including an internal electrical energy source formed by the engine <NUM> and the electrical generating element <NUM> as well as one or more electrical energy sources that are external to the electrical generator <NUM>.

For example, <FIG> illustrates an embodiment where elements that are similar to elements in <FIG> are referenced using the same reference numerals. <FIG> illustrates the electrical generator <NUM> as being connectable to utility lines 57a external to the generator <NUM> that provide input AC power; one or more energy storage devices 57b external to the generator <NUM> such as one or more batteries that provide input DC power; and one or more other electrical energy sources 57c external to the generator that can provide input AC or DC power. A power conversion device 58a receives the AC power from the utility lines 57a and converts the incoming AC to DC. An optional power conversion device 58b may receive DC power from the energy storage device 57b and convert the DC to AC. In addition, a power conversion device 58c receives AC or DC power from the energy source 57c and convert the AC to DC or converts DC to AC.

A switching system <NUM> is provided that can control the flow of electrical power between the power sources <NUM>, <NUM>, 57a-c and the bus <NUM>. For example, the switching system <NUM> may be configured so that any one of the power sources can provide electrical power to the bus <NUM>. The switching system <NUM> may also be configured so that any two or more of the power sources can simultaneously provide electric power to the bus <NUM>. In another embodiment, the switching system <NUM> may be configured so that electrical power is provided from the bus <NUM> to one of the power sources. For example, electrical energy generated from the engine <NUM> can be directed to the utility lines 57a to supply power to the electrical grid or to the energy storage devices 57b. The alternative power sources depicted in <FIG> be used with the systems illustrated in <FIG> and <FIG> as well.

According to the invention, the electrical generators <NUM> described herein also include a thermal control system <NUM> that can be configured to provide a thermal control fluid for thermal control of a component that is external to the electrical generator <NUM>. For example, the thermal control fluid can be provided to the component <NUM> and/or to the component <NUM>. In another example, the thermal control fluid can be provided to a component that is not electrically connected to the electrical generator <NUM>. The thermal control system <NUM> may also be configured to supply the thermal control fluid to one or more components that are internal to the electrical generator <NUM>.

The thermal control fluid can be a liquid, gas, or a mixture of liquid and gas. The thermal control fluid can be a cooling fluid that cools the external/internal component, or a heating fluid that heats the external/internal component. In some embodiments, the system <NUM> may be configured to export a heated liquid for providing heat, either in addition to the cooling liquid or without the cooling liquid. The heated liquid can be used to, for example, heat one of the components <NUM>, <NUM>, and/or heat a component internal to the electrical generator <NUM>, and/or heat any external component or structure such as a control cab, or used for any other purpose. When the system <NUM> exports a heated liquid, the system <NUM> may be referred to as a liquid heating system. The system <NUM> may be referred to as a thermal control system regardless of whether it exports cooling liquid and/or heated liquid for heating.

For sake of convenience, the system <NUM> will hereinafter be described as a liquid cooling system that provides a cooled liquid as the thermal control fluid. <FIG> illustrates one embodiment of the system <NUM> configured as a liquid cooling system. The liquid cooling system <NUM> can include a liquid coolant tank <NUM> that is configured to contain a liquid coolant and act as a supply of the liquid coolant, a coolant pump <NUM> connected to the liquid coolant tank <NUM> for pumping the liquid coolant through the cooling system <NUM>, and a heat exchanger (or chiller) <NUM> for cooling the liquid coolant. In addition, the system <NUM> includes a coolant supply manifold <NUM> with a plurality of outlet ports and an inlet receiving coolant from the coolant pump <NUM>, and a coolant return manifold <NUM> with a plurality of inlet ports and an outlet connected to the heat exchanger/chiller <NUM>. The system <NUM> further includes at least one externally accessible quick disconnect connector <NUM> for directing coolant to, and receiving return heated coolant from, at least one external heat generating component, such as the component <NUM> or a different component, via an umbilical that contains the coolant supply and return lines 28a, 28b (<FIG>). In this example, the cooling system <NUM>, such as the tank <NUM>, the pump <NUM> and the heat exchanger/chiller <NUM>, are disposed within the housing <NUM>.

As described in detail further below with respect to <FIG>, a thermal control fluid supply bus and a thermal control fluid return bus can be provided on the generator <NUM>. The supply bus and the return bus can be connected to in order to supply thermal control fluid to and return thermal control fluid from one of the modules described below in <FIG>, one of the electrical components <NUM>, <NUM>, or any external device that is supplied with thermal control fluid from the generator <NUM>.

In embodiments where the thermal control fluid is a liquid coolant, the liquid coolant can be any liquid coolant that is suitable for cooling the heat producing component. For example, the liquid coolant can be water mixed with an anti-freeze agent such as ethylene glycol or propylene glycol, or an oil-based coolant. The tank <NUM> acts as a reservoir for the liquid coolant to supply coolant and receive returning coolant after performing its cooling function. The pump <NUM> pumps the coolant through the system <NUM>. The pump <NUM> can be an electric motor driven pump that is powered using the electrical power created by the generator <NUM> or mechanically driven via a suitable drive train by the output shaft <NUM> of the engine <NUM>. The heat exchanger/chiller <NUM> receives returning coolant from the return manifold <NUM> and cools the liquid coolant before it is returned into the tank <NUM>. The heat exchanger/chiller <NUM> can have any configuration that is suitable for cooling the liquid coolant. For example, in the case of a heat exchanger, the heat exchanger can be configured as an air-to-liquid heat exchanger or configured as a liquid-to-liquid heat exchanger. Other arrangements of the pump <NUM> and the heat exchanger/chiller <NUM> are possible. For example, the heat exchanger/chiller <NUM> can be located on the supply path of the coolant, for example between the pump <NUM> and the supply manifold <NUM>. In another embodiment, the pump <NUM> can be located on the return path of the coolant, for example between the manifold <NUM> and the heat exchanger/chiller <NUM>.

The supply manifold <NUM> supplies the cooling liquid to various destinations in the cooling system <NUM> via its outlet ports. For example, a supply line 78a can extend from one of the outlet ports in the supply manifold <NUM> to the power converter <NUM> in order to direct the cooling liquid to the power converter <NUM> to cool the power converter <NUM>. In addition, a supply line 78b can extend from another one of the outlet ports in the supply manifold <NUM> to an external outlet in the quick disconnect connector <NUM> (or to a coolant supply bus) to direct the cooling liquid externally of the electrical generator <NUM>. In the illustrated example, the cooling liquid can be directed to both the external power converter <NUM> and an electric drive motor <NUM> that drives the component <NUM> (for example an impeller of a pit pump) for cooling the power converter <NUM> and the electric drive motor <NUM>. In the illustrated example, the cooling liquid is directed serially through the electric drive motor <NUM> and the power converter <NUM>, with the cooling liquid first cooling the electric drive motor <NUM> and then being directed into the power converter <NUM> to cool the power converter <NUM> before the cooling liquid is directed back to the electrical generator <NUM>. In another embodiment, the cooling liquid can be directed to the power converter <NUM> first before being directed to the electric drive motor <NUM>. In still another embodiment, the cooling liquid can be directed to the power converter <NUM> and the electric drive motor <NUM> in parallel where separate streams of the cooling liquid are directed to the power converter <NUM> and the electric drive motor <NUM>. In some embodiments, if the power converter <NUM> is not present or does not need cooling, the cooling liquid could be supplied just to the electric drive motor <NUM> to cool the electric drive motor <NUM>. Similarly, in some embodiments, of the electric drive motor <NUM> does not require cooling or is not present, the cooling liquid can be supplied just to the power converter <NUM>.

With continued reference to <FIG>, in some embodiments, other internal components of the electrical generator <NUM>, such as the electrical generating element <NUM> and the power converter <NUM>, may also be configured to be liquid cooled. In such a case, supply lines 78c, 78d extend from respective outlet ports in the supply manifold <NUM> to the electrical generating element <NUM> and the power converter <NUM>. An optional bypass loop <NUM> may also be provided that extends between the supply manifold <NUM> and the return manifold <NUM>. The bypass loop <NUM> helps to increase the cooling capacity of the system <NUM>.

The return manifold <NUM> receives the returning heated liquid coolant from the various cooling destinations in the cooling system <NUM>. For example, a return line 82a extends from the power converter <NUM> to one of the inlet ports in the return manifold <NUM>, and a return line 82b extends from an external inlet in the quick disconnect connector <NUM> (or from a coolant return bus) to one of the inlet ports in the return manifold <NUM>. Additional return lines 82c, 82d extend from the electrical generating element <NUM> and the power converter <NUM>, respectively, to respective inlet ports in the return manifold <NUM>.

Optionally, temperature sensors <NUM> and flow meters <NUM> can be provided in the return lines 82a-d. The temperature sensors <NUM> and the flow meters <NUM> provide data that is useful for providing health monitoring and/or performance optimization of the electrical generator <NUM> and its components, as well as health monitoring and/or performance optimization of the heat generating component(s) <NUM>. Data from the temperature sensors <NUM> and the flow meters <NUM> can be fed to suitable control logic to monitor these parameters. Variations in the individual temperatures and flows of the cooling liquid can indicate problems with the respective elements including, but not limited to, elements <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, etc., and suitable signals can be generated to warn an operator of a problem or potential problem.

<FIG> is a schematic depiction of a variation of the thermal control system <NUM> from <FIG>. In the system <NUM> in <FIG>, elements that are the same as elements in <FIG> are referenced using the same reference numbers. The system <NUM> in <FIG> is similar to the system <NUM> in <FIG>, with the tank <NUM>, the pump <NUM>, the heat exchanger <NUM>, the supply manifold <NUM>, and the return manifold <NUM> internal to the housing <NUM>.

The system <NUM> in <FIG> differs from <FIG> in that a flow selector <NUM> is provided in the system <NUM> that can be used to divert the flow of the coolant from the return manifold <NUM> to an external heat exchanger/chiller <NUM>. The heat exchanger/chiller <NUM> can be connected to the generator via quick connect connectors <NUM> or any other suitable form of fluid connector. In this embodiment, the flow selector <NUM> can be actuated so as to permit flow of the cooling liquid directly from the return manifold <NUM> to the internal heat exchanger/chiller <NUM>. The flow selector <NUM> can also be actuated so as to direct flow of the cooling liquid from the return manifold <NUM> to the external heat exchanger/chiller <NUM>, before flowing back into the generator to the internal heat exchanger/chiller <NUM>. Although the heat exchanger/chiller <NUM> is depicted as being a stand-alone component, the heat exchanger/chiller <NUM> can be incorporated into the component <NUM> and/or into the component <NUM>. In some embodiments, one or more additional quick connect connectors <NUM> (shown in dashed lines) can be provided for connection with additional external devices.

With continued reference to <FIG>, external components can also be connected in series and/or parallel to the flow of the cooling liquid for cooling the external components. For example, <FIG> illustrates <NUM> external components 96a, 96b, 96c fluidly connected to and receiving cooling liquid via the supply line 78a. The components 96a, 96b are fluidly connected in series whereby the cooling liquid flows through and cools the component 96a before flowing to and cooling the component <NUM>, and then being returned to the return manifold <NUM>. The component 96c is fluidly connected in parallel with the component 96b, where a portion of the cooling liquid is diverted from the component 96a to the component 96c for cooling the component 96c before being returned to the return manifold <NUM>. In other embodiments, the cooling liquid can be diverted to the components 96b, 96c before flowing into the component 96a.

<FIG> is a schematic depiction of another variation of the thermal control system <NUM> from <FIG> and <FIG>. In the system <NUM> in <FIG>, elements that are the same as elements in <FIG> and <FIG> are referenced using the same reference numbers. The system <NUM> in <FIG> is similar to the system <NUM> in <FIG> and <FIG>, with the tank <NUM>, the pump <NUM>, the heat exchanger <NUM>, the supply manifold <NUM>, and the return manifold <NUM> internal to the housing <NUM>.

The system <NUM> in <FIG> differs from the system in <FIG> in that the cooling liquid from the supply line 78a initially flows into a first external component, such as the component <NUM>, to cool the first external component, and the cooling liquid is then directed into and cools the second external component, such as the component <NUM>, before being returned to the return manifold <NUM>. In the embodiment in <FIG>, the system <NUM> is configured so that the first and second external components receive the cooling liquid in series. In another embodiment, the first and second external components can receive the cooling liquid in series, with the second external component receiving the cooling liquid first followed by the first external component receiving the cooling liquid before returning to the return manifold <NUM>.

In some embodiments, the electrical generator <NUM> can include the two outputs <NUM>, <NUM> without the thermal control system <NUM> of <FIG>. In other embodiments, the electrical generator <NUM> can include only one of the outputs <NUM>, <NUM> together with the thermal control system <NUM> of any one of <FIG>.

Referring to <FIG>, an embodiment of a control system architecture <NUM> of the electrical generator <NUM> is illustrated. Elements that are the same as elements in <FIG> are referenced using the same reference numbers. A removable and replaceable user interface module <NUM> is installed on the electrical generator <NUM> for controlling operation of the electrical generator <NUM> based on the component <NUM> that is connected to or to be connected to the modulated electrical output, or optionally based on the component <NUM> that is connected to or to be connected to the export electrical power output. Instead of being installed on the electrical generator <NUM>, the user interface module <NUM> can be used remotely from the electrical generator <NUM> (as indicated in broken line) to control the electrical generator <NUM>.

In some embodiments, the user interface module <NUM> can be replaced with one of a plurality of additional user interface modules 102a. 102n each one of which is specifically configured to be installed on the electrical generator <NUM> depending upon the external component <NUM> to be powered by the generator <NUM>. Each user interface module <NUM>, 102a,. 102n is specifically configured for use with its associated external component <NUM> to control the electrical generator <NUM> to ensure that the correct electrical power required by the component <NUM> is supplied at the modulated electrical output <NUM>. Since each different component <NUM> that may be connected to the modulated electrical output <NUM> may require a different modulated electrical power, the modulated electrical power at the modulated electrical output <NUM> can be different for each user interface module <NUM>, 102a,. The user interface modules <NUM>, 102a,. 102n can individually and removably plug into a module mounting location <NUM> on the electrical generator <NUM>. In other embodiments, instead of adding a new interface module, the programming of the interface module <NUM> can be changed or added to in order to add a new component <NUM> so that the interface module <NUM> can be used with each new component <NUM> by modifying the programming of the interface module <NUM> based on each new component <NUM>.

With continued reference to <FIG>, the control system architecture <NUM> is also illustrated as including a Bluetooth module <NUM> that can connect to a smart device, such as a smart phone or tablet, via Bluetooth to receive feedback from the electrical generator <NUM> and to permit control of the electrical generator <NUM> by the smart device, a communication modem <NUM> to permit remote connection to a remote controller, such as a personal computer or the like, to receive feedback from the electrical generator <NUM> and to permit control of the electrical generator <NUM> by the remote controller, a slave module <NUM> that receives sensor signals and outputs all control signals for the electrical generator <NUM>, and an isolation monitor <NUM> that forms an electrical safety system that monitors electrical isolation between the chassis of the electrical generator <NUM> and high voltage.

The electrical generator <NUM> described herein can be used at any location where electrically powered components that require different types of electrical power are utilized. One specific application of the electrical generator <NUM> will be described with respect to <FIG>. In this example application, the electrical generator <NUM> is used at a site where horizontal directional drilling is occurring. In particular, the site includes a horizontal directional drilling (HDD) rig <NUM> and a pit pump <NUM>. The HDD rig <NUM> is configured to perform horizontal directional drilling which is well known to those of ordinary skill in the art. The HDD rig <NUM> can be electrically powered with components such as traverse carrier drive components and drill pipe rotation components driven by electric motors. The HDD rig <NUM> can also include other electrically powered components such as a chiller system that is part of a cooling fluid circuit that circulates and cools a refrigerant liquid that is circulated through various ones of the electric motors on the HDD rig <NUM> for cooling the electric motors. An example of an electrically powered HDD rig <NUM> is disclosed in <CIT>.

The pit pump <NUM> is disposed in a pit <NUM>, submerged in drilling fluid, and is configured to pump the drilling fluid to a recycling system of the HDD rig <NUM> to be recycled for re-use by the HDD rig <NUM>. The pit pump <NUM> is part of a drilling fluid recycling system that is used to recycle used drilling fluid for re-use during a borehole drilling operation. Used drilling fluid from the drilling operation, mixed together with solids from the borehole, can collect in the pit <NUM>, which can be an exit pit or an entry pit, with the used drilling fluid mixed with solids then being pumped by the pit pump <NUM> to the rest of the recycling system where the used drilling fluid is processed to remove the solids and to make the drilling fluid otherwise suitable for pumping back into the borehole. The construction and operation of a drilling fluid recycling system in a HDD system is well known in the art. The pit pump <NUM> includes an electric drive motor (such as the motor <NUM> shown in <FIG>) that drives a pump impeller. A suitable pit pump is available from LaValley Industries of Bemidji, Minnesota.

With continued reference to <FIG>, the drive motor of the pit pump <NUM> is electrically connected to the output <NUM> to receive the modulated electrical power for powering the drive motor. At the same time, one or more electrical components on the HDD rig <NUM> (or other electrical component(s) at the drilling site) can be electrically connected to the output <NUM> to receive the export electrical power. In addition, with reference to <FIG> and <FIG>, the drive motor of the pit pump <NUM> may be configured to be liquid cooled, in which case the drive motor is fluidly connected to the quick disconnect connector <NUM> of the electrical generator <NUM> to receive cooling fluid or other thermal control fluid from the thermal control system <NUM> thereof for cooling the drive motor, with the cooling fluid then being recirculated back to the electrical generator <NUM> for removing heat from the cooling fluid.

With reference to <FIG>, in one embodiment, the electrical generator <NUM> can adjust a temperature of the thermal control fluid directed to the external component(s). For example, a fan of the internal heat exchanger/chiller can be turned on/off and/or the thermal control fluid can be directed to the external heat exchanger/chiller <NUM> to adjust the temperature of the thermal control fluid. The temperature of the thermal control fluid can be determined using suitable temperature sensor(s), for example the temperature sensor <NUM> in the return line 82b and/or a temperature sensor in the supply line 78b and/or a temperature sensor on the output from the tank <NUM>. When the external component to be thermally controlled is an electric drive motor, such as the electric drive motor of the pit pump <NUM>, adjusting the temperature of the thermal control fluid directed to the drive motor adjusts the performance capacity/efficiency of the electric drive motor, e.g. adjusts the power or revolutions per minute (RPMs) of the electric drive motor because the electric drive motor is more efficient the cooler it is.

In one embodiment of the electrical generator <NUM> described herein, the RPM's of the engine can be varied based on the load connected to the output <NUM> in order to maximize the operating fuel efficiency of the engine <NUM> based on the specific load. In addition, the export electrical power at the output <NUM> allows the generator <NUM> to operate traditional synchronous electrical loads at all common voltages including <NUM> V, <NUM> V, <NUM> V, etc. By providing both the modulated electrical power and the export electrical power, either one can be used at full power (i.e. the modulated electrical power can output <NUM>% of the electrical generator <NUM> power capacity with the export electrical power outputting <NUM>%; or the export electrical power can output <NUM>% of the electrical generator <NUM> power capacity with the modulated electrical power outputting <NUM>%). In addition, the power can be split between both the modulated electrical power and the export electrical power simultaneously. If the electrical generator <NUM> has more than two electrical outputs, the power can be split among the various electrical outputs. The power can be split in any ratio. However, the available generator power (i.e. <NUM>% capacity) cannot be exceeded. In one embodiment, power can be prioritized by the control system of the electrical generator <NUM> to the external component <NUM>, <NUM> that needs the most power. The prioritization can be manually set or automatically set based on communications from the component(s) <NUM>, <NUM>. For example, when a component <NUM>, <NUM> is connected to the generator <NUM>, the component <NUM>, <NUM> can inform the generator <NUM> of its power requirements and thus of its priority.

In the embodiments described herein, either output type can be selected as a priority. For example, if the modulated electrical power is selected as a priority, the export electrical power will be reduced in proportion to any increase in the modulated electrical power so that the total remains <NUM>%. Likewise, if the export electrical power is selected as a priority, the modulated electrical power will be automatically reduced in proportion to any increase in the export electrical power so that the total remains <NUM>%. For example, with the modulated electrical power selected as a priority, as the modulated electrical power increases toward <NUM>%, the export electrical power will be automatically decreased proportionally toward <NUM>%.

In addition, in the embodiments described herein, a user can also be permitted to select a power ratio limit that will, if needed, automatically limit the modulated electrical power and the export electrical power to the selected ratio. For example, if one selects a ratio of <NUM>%-<NUM>% of the modulated electrical power versus the export electrical power, the modulated electrical power would be limited to a maximum of <NUM>% of the total generator capacity if the device(s) using export electrical power is using its allotted <NUM>% limit of the total generator capacity. In this example, if the device(s) using export electrical power is using only <NUM>% (or some other value less than <NUM>%) of the total generator capacity, the modulated electrical power can exceed the <NUM>% limit by a corresponding amount. However, if the device(s) using the export electrical power then increases to <NUM>%, the modulated electrical power would then be reduced to the <NUM>% limit.

The electrical generator <NUM> also provides fuel savings by the unique system architecture that provides the modulated electrical power which allows the engine <NUM> to operate at lower RPM's when the load is lower reducing power consumption and unnecessary wear. Health monitoring can also be provided on the components of the electrical generator <NUM> to provide state of the art feedback of all critical operating parameters such as duty cycle, temperature, peak cycle, vibration, and the like. Each of the components including, but not limited to, the components <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>', <NUM>, <NUM>' <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, etc., can be monitored using temperature sensors, and other sensors, which readings can be fed directly to the user interface module <NUM>, or to the slave module <NUM> and then the user interface module <NUM>. The readings serve to provide health monitoring of the various components of the electrical generator <NUM> and used with the generator <NUM>.

With reference to <FIG>, in one embodiment two or more of the electrical generators <NUM> can be connected in parallel to increase capacity in electrically driving a load, for example driving the component <NUM> and/or driving the component <NUM>. Further description on paralleling two or more electrical generators is discussed below with respect to <FIG> and <FIG>.

<FIG> illustrate another embodiment of the electrical generator <NUM>. In this embodiment, the electrical generator <NUM> uses a plurality of modules, including output modules that incorporate the different electrical outputs <NUM>, <NUM>. The internal components of the generator <NUM> in <FIG> can be similar to the generator <NUM> in <FIG>, including the engine <NUM> (or other AC input power source), the output shaft <NUM>, the electrical generating element <NUM>, the first power converter <NUM>, and the thermal control system <NUM>. In some embodiments, one or more of the power converters may also be included in the generator of <FIG>. However, in the embodiment of <FIG>, the power converters <NUM>, <NUM>', <NUM>-<NUM>, <NUM>-<NUM>, <NUM>, <NUM>' described herein are preferably included within output modules that are removably installable in the electrical generator <NUM>.

For example, with continued reference to <FIG>, the generator <NUM> can include a first power output module <NUM>, a second power output module <NUM>, and optionally a third power output module <NUM>. The first power output module <NUM> can be configured to output, via the electrical output <NUM> incorporated into the module <NUM>, the desired form of AC electrical power for powering the component <NUM>. The module <NUM> includes the power converter <NUM>, <NUM>' that converts the DC power from the DC bus to the desired form of AC electrical power. Similarly, the second power output module <NUM> can be configured to output, via the electrical output <NUM> incorporated into the module <NUM>, the desired form of AC electrical power for powering the component <NUM>. The module <NUM> includes the power converter <NUM>, <NUM>' that converts the DC power from the DC bus to the desired form of AC electrical power. The optional third power output module <NUM> can be configured to output a lower power from the electrical output <NUM>-<NUM>, such as AC electrical power with a lower voltage than the output <NUM>, for example as described above with respect to the output <NUM>-<NUM> of <FIG>. The module <NUM> includes the power converter <NUM>-<NUM> that converts the DC power from the DC bus to the desired form of lower power AC electrical power.

The power output modules <NUM>, <NUM>, <NUM> are each removably installed in the generator <NUM>. As a result, the power output of the generator <NUM> can be modified by using any combination of the modules <NUM>, <NUM>, <NUM>, and/or replacing one of the modules <NUM>, <NUM>, <NUM> with a similar module that is configured with a different power converter to change the AC electrical power output therefrom. In some embodiments, a separate module, or one of the power output modules <NUM>, <NUM>, <NUM>, can be configured to output DC power therefrom which DC power is modified from the form obtained from the DC bus. In some embodiments, instead of having a module that modifies the DC power, the DC power from the DC bus need not be modified and unmodified DC power from the DC bus can be output directly from the DC bus including from a power output module.

Each power output module can be configured based on the device intended to be connected to the power output module and/or based on the function of the power output module. For example, if the pit pump <NUM> of <FIG> is to be connected to the generator <NUM>, the power output module to be connected to by the pit pump is configured to output electrical power suitable for the pit pump <NUM>. Similarly, if a component on the HDD rig <NUM> of <FIG> is to be connected to the generator <NUM>, the power output module to be connected to by the HDD rig component is configured to output electrical power suitable for the HDD rig component. The electrical generator <NUM> may also be used to charge an electric vehicle (EV) in which case a power output module, which may be referred to an EV charging module, is configured to output electrical power suitable for charging the EV. Many other examples of power output modules are possible.

With continued reference to <FIG> and <FIG>, the first power output module <NUM> can also include a data port <NUM> for exporting data from and/or inputting data into the module <NUM>. In addition, the module <NUM> can also include thermal control fluid inlet and outlet ports 128a, 128b that can be used to direct thermal control fluid from the internal thermal control system <NUM> of the generator <NUM> to the component <NUM> receiving power from the module <NUM>. The thermal control fluid from the internal thermal control system <NUM> can be input into the module <NUM> via suitable fluid connectors (not shown) on the rear of the module <NUM> that are fluidly connected to fluid connectors <NUM> (see <FIG>) within the generator <NUM>. The fluid connectors <NUM> can be configured for manual connection, or they can be blind mate, quick connect fluid couplers. The fluid connectors <NUM> can be part of a thermal control fluid bus assembly formed on each one of the generators <NUM>, with one of the fluid connectors <NUM> of each pair of fluid connectors <NUM> connected to a thermal control fluid supply bus that is fluidly connected to the supply manifold <NUM> (see <FIG>) and the other one of the fluid connectors <NUM> of each pair being connected to a thermal control fluid return bus that is fluidly connected to the return manifold <NUM> (see <FIG>). The thermal control fluid directed into the module <NUM> can also be used to thermally control the internal power converter and other heat generating components of the module <NUM>. If desired, thermal control fluid inlet and outlet ports similar to the ports 128a, 128b can also be provided on the modules <NUM>, <NUM>.

Returning to <FIG>, the generator <NUM> can also include a paralleling module <NUM> and at least one module expansion slot <NUM> covered by a removable cover <NUM>. The paralleling module <NUM> is configured for interconnecting the generator <NUM> in parallel with one or more additional ones of the generators <NUM> as illustrated in <FIG>. For example, in the illustrated embodiment, the paralleling module <NUM> is provided with upper, input and lower, output rows 138a, 138b of positive, negative and ground terminals for connecting the generators <NUM> in parallel using suitable paralleling cables <NUM> depicted in <FIG>. Returning to <FIG>, the module expansion slot <NUM> is configured to permit the addition of one or more additional modules <NUM> (depicted in dashed lines in <FIG>) to the generator <NUM> when the cover <NUM> is removed. The additional module <NUM> can be an additional one of the power output modules <NUM>, <NUM>, <NUM>. In another embodiment, the additional module <NUM> can be a thermal control module used for thermally controlling the thermal control fluid, for example the thermal control module can include the external heat exchanger/chiller <NUM> described above with respect to <FIG> and <FIG>. In still another embodiment, the additional module <NUM> can be used as a thermal control module that acts as a cooling and/or heating module. When configured as a cooling module, the module can act as a source for directing additional flows of the liquid coolant from the internal liquid cooling system <NUM> of the generator <NUM> to external devices needing cooling. When configured as a heating module, the module can direct heated coolant externally for heating use, for example to heat a building, a control cab of an HDD rig, or other heating need. The thermal control module can also include a plurality of liquid inlet and outlet ports on the front side thereof permitting connection of fluid lines for directing the cooled liquid coolant to one or more external devices needing cooling or directing the heated coolant to one or more external devices needing heating.

Referring to <FIG> and <FIG>, electrical power for the modules <NUM>, <NUM>, <NUM>, <NUM> of the generator <NUM> can be provided via DC bus bars <NUM> that form the DC output bus <NUM> of the generator <NUM>. Each one of the modules is configured to electrically connect to the DC bus bars <NUM>. The modules can electrically connect to the DC bus bars <NUM> in any suitable manner. For example, as best seen in <FIG>, the rear side of the each module can include electrical connectors <NUM> that connect to the DC bus bars <NUM>. The electrical connectors <NUM> can be blind mate electrical connectors that automatically connect to the DC bus bars <NUM> when each module is slid into position in its slot in the generator <NUM>, and that automatically disconnect from the DC bus bars <NUM> when each module is removed from the generator <NUM>. Similarly, the modules <NUM>, <NUM>, <NUM>, <NUM> can each include blind mate, quick connect fluid couplers that automatically blind mate connect with the blind mate, quick connect fluid couplers <NUM> when each module is slid into position in its slot in the generator <NUM>, and that automatically disconnect when each module is removed from the generator <NUM>.

<FIG> illustrates a plurality of the generators <NUM> connected to one another in parallel. In the illustrated example, the generator <NUM> on the right is configured to output electrical power via the output modules <NUM>, <NUM>, <NUM>. The generator <NUM> on the right is able to supply <NUM>% of the electrical power that is available from all of the generators <NUM>. However, modules can be added to any of the generators <NUM>. For example, the second generator <NUM> is illustrated as including the output module <NUM> (in dashed lines) and the output module <NUM> (in dashed lines). The generators <NUM> have a common bus connection. The modules can be located in any generator <NUM> and connect to the common bus while sharing the single common bus power source.

Any generator <NUM> can be contributing as little or as much electrical power to the bus as needed. Load management control can be used to shed generators <NUM> or bring generators <NUM> on as needed without changing connections between the generators <NUM> since there is a single common bus. In particular, the RPMs of the engines <NUM> of the paralleled generators <NUM> can be automatically controlled. For example, in the case of multiple paralleled generators <NUM>, all of the generators <NUM> may be controlled so as to adjust their RPMs up or down as needed to match the system load. If the system load that is required becomes less than the paralleled generators <NUM> are producing, then one or more of the generators can be shed (i.e. shut down or its power output not contributing to the total power output of the paralleled generators) as needed. If the system load thereafter increases, then one or more of the generators can be brought back on as needed to contribute to the total power output as.

<FIG> illustrates the common DC bus connection of the paralleled electrical generators <NUM> of <FIG>. Each generator <NUM> contributes to the common DC bus <NUM> of the system, and each output module <NUM>, <NUM>, <NUM> draws electrical power from the common DC bus <NUM> for powering its associated load (e.g. components <NUM>, <NUM>). In some embodiments, the bus <NUM> can be an AC bus.

So the configurations in <FIG> permit electrically connecting a plurality of the generators <NUM> in parallel via a DC bus. In addition, the performance of the generator <NUM> can be modified by replacing one of the modules, for example one of the power output modules <NUM>, <NUM>, <NUM>, with another module that is configured to have different performance, for example outputting a different amount or type of AC power or DC power in the case of the power output modules <NUM>, <NUM>, <NUM>.

<FIG> illustrates another example of a common bus connection. Elements in <FIG> that are the same as elements in <FIG> are referenced using the same reference numerals. In <FIG>, a plurality of the electrical generators <NUM> are depicted as being connected in parallel. In addition, one or more energy storage devices, which can be similar to the energy storage device 57b of <FIG>, may also be connected to the bus <NUM>. The energy storage device(s) 57b can be part of or separate from the electrical generator(s) <NUM> and can be used to store electrical energy generated by the electrical generator(s) <NUM>. The energy storage device(s) 57b can be any energy storage device that can store electrical energy. For example, the energy storage device(s) 57b can be one or more batteries, capacitors, and the like. The energy storage device(s) 57b may also be used to provide electrical power for use by the output modules <NUM>, <NUM>, <NUM>, or the energy storage device(s) 57b can be used to provide electrical power for any device external to the electrical generator(s) <NUM>. When the energy storage device(s) 57b is provided, a power output module <NUM>, <NUM>, <NUM> that is configured for use in outputting electrical energy from the energy storage device(s) 57b and/or controlling charging of the energy storage device(s) 57b can be provided.

<FIG> illustrates another example of a common bus connection. Elements in <FIG> that are the same as elements in <FIG> and <FIG> are referenced using the same reference numerals. <FIG> depicts one or more of the electrical generators <NUM> connected to the bus <NUM> along with the utility lines 57a, one or more of the energy storage devices 57b, and the other energy source 57c. Referring to <FIG> and <FIG>, the generator <NUM> acts as an energy handling system, where the electrical bus <NUM> is electrically connectable to a first source of electrical power within the housing <NUM> or enclosure, and is also electrically connectable to a second source of electrical power external to the enclosure, such as the utility lines 57a, the energy storage 57b and/or the other energy source 57c. In addition, a plurality of electrical power outputs can be provided, for example via the output modules <NUM>, <NUM>, <NUM>, where the power outputs can be connected to in order to direct electrical power to the external loads <NUM>, <NUM> that are external to the housing/enclosure. In some embodiments, the bus <NUM> can receive electrical power from the second, external source of electrical power and the bus <NUM> can also be used to direct electrical power to the second, external source of electrical power, for example to direct excess electrical power to the electrical grid via the utility lines 57a and/or to charge the energy storage device(s) 57b.

<FIG> illustrates another embodiment where the bus <NUM>, and a supply manifold <NUM> and a return manifold <NUM> for the thermal control fluid are integrated together in a common assembly <NUM> (illustrated schematically by the dashed line box). In <FIG>, elements that are identical or similar to elements previously described above are referenced using the same reference numerals. The common assembly <NUM> forms a common structure where both electrical energy transfer and thermal energy transfers take place. The common assembly <NUM> can be integrated into the electrical generator structures described herein. In another embodiment, the common assembly <NUM> can be a structure that is physically separate from the electrical generator structures described herein, but which can be interfaced with the electrical generator structures described herein.

Different sources of electrical power can electrically connect to the bus <NUM> of the common assembly <NUM> to direct electrical power into the bus <NUM> and/or to receive electrical power via the bus <NUM>. The sources of electrical power can include, but are not limited to, the engine <NUM> and the generator <NUM>, the utility lines 57a, the energy storage devices 57b, a solar panel array 57d, a fuel cell 57e, or a microturbine 57f. Power conversion devices 58d, 58e, 58f are connected to the array 57d, the fuel cell 57e and the microturbine 57f, respectively, to convert and/or condition the electrical energy in a manner making it suitable for input to the bus <NUM>. <FIG> depicts the utility lines 57a feeding electrical power to and/or receiving electrical power from the power conversion device <NUM> via a transfer switch <NUM>. However, the utility lines 57a can have their own power conversion device, like the power conversion device 58a in <FIG>.

With continued reference to <FIG>, different power consuming components can be electrically connected to the assembly <NUM> to receive electrical power from the bus <NUM> and/or to receive thermal control fluid from the supply manifold <NUM>. The power consuming components can be any components that can be powered by electrical power received from the assembly <NUM> and/or that can receive thermal control fluid from the assembly <NUM> for use in thermal control of the power consuming component. For example, the components can be the components <NUM>, <NUM>, a component <NUM> that can be directly powered from DC (or AC) power of the bus <NUM> (i.e. without requiring a power converter), a DC powered component <NUM> that has a DC/DC power converter <NUM>, an AC higher powered component <NUM> that has a DC/AC power converter <NUM> providing higher AC power, and an AC lower powered component <NUM> that has a DC/AC power converter <NUM> providing lower AC power (i.e. lower than the DC/AC power converter <NUM>).

One or more of the power consuming components in <FIG> can also be fluidly connected to the supply manifold <NUM> and the return manifold <NUM> for directing thermal control fluid to and from the power consuming component(s) for performing thermal control of components on or associated with the power consuming components. For example, for each power consuming component, a supply line <NUM> fluidly connects the power consuming component and the supply manifold <NUM> to direct incoming thermal control fluid to the power consuming device, and a return line <NUM> fluidly connects the power consuming component and the return manifold <NUM> to direct returning thermal control fluid from the power consuming device to the heat exchanger/chiller <NUM>.

<FIG> also depicts a control system <NUM> that can be used to control some or all of the system depicted in <FIG>. For example, the control system <NUM> can be in communication with the pump <NUM> and each of the power sources <NUM>, 57a, 57b, 57d, 57e, 57f. The control system <NUM> can also be in communication with the power conversion devices <NUM>, 58b, 58d, 58e, 58f, flow control valves <NUM> in the supply line <NUM> and the return line <NUM>, and communication interfaces <NUM> associated with the power consuming components <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>. The control system <NUM> can receive data inputs from the various elements to allow monitoring of performance. The control system <NUM> can also control operation of the various elements. For example, the control system <NUM> can determine which electrical power source(s) <NUM>/<NUM>, 57a, 57b, 57d, 57e, 57f supplies electrical power to the bus <NUM> and/or direct electrical power from one power source, such as the power source <NUM>/<NUM>, to the utility lines 57a and/or to the energy storage devices 57b. The control system <NUM> can also control the flow of thermal control fluid to and from the power consuming devices by controlling the flow control valves <NUM>.

<FIG> illustrates a non-limiting example of how the bus <NUM>, and the supply manifold <NUM> and the return manifold <NUM>, can be integrated together in the common assembly <NUM>. In this example, metallic pipes forming the supply manifold <NUM> and the return manifold <NUM> form the bus <NUM>, with the pipe of the supply manifold <NUM> forming the positive portion of the bus <NUM> and the return manifold <NUM> forming the negative portion of the bus <NUM>. The pipes can be formed of any material suitable for conducting electricity sufficient to act as a DC (or AC) bus. For example, the pipes can be made of metal including, but not limited to, copper, brass or aluminum. However, other techniques for integrating the bus <NUM> and the manifolds <NUM>, <NUM> into the common assembly <NUM> are possible.

<FIG> also depicts an example of how the power consuming components <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> can be fluidly and electrically connected to the assembly <NUM>. For example, the hoses forming the supply line <NUM> and the return line <NUM> can be electrically conductive, and the control valves <NUM> can be zero leak fluid connectors that are also electrically conductive. Electrically conductive hoses and fluid connectors are known in the art and available from Parker Hannifin Corporation.

Claim 1:
An electrical generator (<NUM>) comprising:
an electrical bus (<NUM>, <NUM>, <NUM>) within the electrical generator, the electrical bus is electrically connectable to a first source (<NUM>, <NUM>) of electrical power within the electrical generator and to a second source (57a, 57b, 57c, 57d, 57e, 57f) of electrical power external to the electrical generator;
a plurality of electrical power outputs (<NUM>, <NUM>) electrically connected to and receiving electrical power from the electrical bus that provide electrical power to external loads (<NUM>, <NUM>) that can be electrically connected to the electrical power outputs;
the electrical generator being characterized in that it comprises:
a plurality of power output modules (<NUM>, <NUM>, <NUM>) each of which is removably installable on the electrical generator, each power output module includes a bus connector (<NUM>) that electrically connects to the electrical bus when the power output module is installed on the electrical generator;
a supply manifold (<NUM>, <NUM>) that supplies a thermal control fluid and a return manifold (<NUM>, <NUM>) that receives returning thermal control fluid, and each power output module is fluidly connected to the supply manifold and to the return manifold.