IL266432A - A hybrid high power generator for charging a bank of batteries with short stabilization and charging times - Google Patents

Description

1 A Hybrid High Power Generator for Charging a Bank of Batteries with Short Stabilization and Charging Times Technical Field The present invention pertains to a high power current/voltage generator system and particularly to a hybrid high power current/voltage generator with a highly short stabilization locking time and charging times and low loss which can further operate over long time period.

Background Hybrid AC/DC electrical power-supply systems comprise an engine-generator system, an energy storage unit, such as a rechargeable battery pack and an electrically connected load. In these systems the electric generator, driven by the engine, charges the energy storage units. These systems are designed to supply the AC/DC voltage/current to at least one electrical connected load in direct or indirect means via a direct electrical feeding means or through a pre-charged energy storage unit, respectively. The electrical feeding method is selected depending on the requirements and availability of electrical power from the connected load at a certain specific time period. This system can be stationary or portable depending on the certain required application. US patent application No. 2007/182158 discloses a moderate 10-70 KW generator which includes an internal combustion engine, a DC generator and one or more battery cells. This system is further connected to an inverter unit which can transform the DC voltage to an AC one. US 7,105,938 discloses a portable moderate size power magnitude electrical AC/DC current/power generator that comprises a generator driven by a heat engine, which is operated by control means further carrying an electrical load. Other similar prior arts such as EP 2629397 disclose a method of recharging the batteries using a DC generating unit for supplying electric power to electric load and WO 2014/054380 disclosing a charger generator, driven by an engine, which charges a battery pack of an electric device.

The main performance deficiencies of these portable AC/DC power supply systems involve rather long charging times of the rechargeable pack of batteries, driven by the stabilization locking time and magnitude of the DC charging current values. 2 Furthermore, these systems exhibit low values of electrical and mechanical power efficiencies mainly due to rather low efficiency of electro-mechanical transmission power means with low values of current charging magnitude from the coupled generator, which is driven by a mechanically coupled engine. In most cases, the performance deficiencies limit the prior arts to low or moderate power applications of civil and industrial apparatuses and systems. Hence, it prevents them from being utilized efficiently in high power industrial and also military applications, which require portable/movable AC/DC power supply systems and apparatuses, which are required to electrically feed high power starving loads over long time periods. Hence, these applications cannot utilize such apparatuses and methods to scale up their performance to high power AC/DC applications of high power AC/DC supply systems with poor and non-beneficial electrical efficiencies.

It is, therefore, an object of the present invention to provide controlling means, which is able to stabilize on high current target values at a significantly short time and exhibit a rather short charging time of a plurality of batteries at significantly short time.

It is yet another object of the present invention to provide application, which operates with high electro-mechanical transmission efficiency with low loss and high mechanical and electrical power efficiencies.

It is yet another object of the present invention to provide application which operates at high AC/DC electrical power supply over long time periods.

It is yet another object of the present invention to provide controlling and monitoring means and methods, which monitor the status of the power supply different components, regulate the AC/DC current of the engine coupled generator and optimize the time of the charging process.

It is yet another object of the present invention to provide a system with a controller which is configured to couple and decouple the various components of the generator supply system such as the engine, the driven voltage generator and the set of storage 3 battery units, to optimize the power loss, charging time, and the AC/DC power supply magnitude to a plurality of electrically attached loads.

This and other objects and embodiments of the invention shell become apparent as the description proceeds.

Summary In one aspect, the present invention is a hybrid high power current/voltage generator that sustains a high voltage/current supply for long time periods of a rechargeable bank of batteries.

In another aspect, the present invention provides a current/voltage generator which exhibits low loss, and highly efficient electrical performance with a short stabilization locking time and a relatively short charging time. The high power hybrid generator can be promptly charged and supply high electrical AC/DC power over a long time period.

In yet another aspect, the present invention discloses a system which provides maximum versatility and can operate in various outdoor locations under different environment and weather, temperature and humidity conditions.

In another aspect of the present invention the disclosed system provides a controller (labeled Genset controller) and coupling and decoupling means, which is configured to couple and decouple the various components of the AC/DC supply system such as the engine, the driven voltage generator and the set of storage battery units, in order to optimize the power loss, minimize the charging time and the AC/DC power supply magnitude to a plurality of electrically attached loads.

In one embodiment, the present invention discloses a hybrid, high power generator system comprising: - a high power DC current supply generator (labeled as Genset) with an input mechanical and electrical interface means for coupling an external driving 4 engine/motor with at least one electrical monitoring input interface for the output voltage and current of the DC current supply generator/Genset and at least one electrical input interface for regulation of the output voltage of the DC current supply generator; - an engine/motor which is mechanically coupled to a DC high power current supply generator/Genset through the input of the mechanical and electrical interface means; - an electrical Genset controller comprising a plurality of monitoring and voltage regulating means; and - a battery bank comprising a plurality of rechargeable batteries with electrical charging and electrical monitoring interface means, wherein the Genset controller is electrically connected to the generator/Genset through the electrical interface means of the DC high power current supply generator/Genset for monitoring the values of its output current and voltage magnitudes, wherein the Genset controller regulating means are electrically connected to the voltage output of the DC high power current supply generator/Genset through the input regulating interface means, regulating its output voltage in the electrical generator/Genset stabilization locking and charging steps, wherein the Genset controller regulating means are connected to the battery bank through the electrical input interface means of the battery bank and monitor its electrical voltage during the charging time period.

In another embodiment, the engine/motor is a DC diesel fuel engine/motor.

In yet another embodiment, the Genset controller monitoring means are connected through the electrical interface means for monitoring the battery bank electrical parameters such as the instantaneous capacitance, resistance, voltage and charge accumulation of the plurality of rechargeable batteries.

In still a further embodiment of the present invention, the Genset controller monitors the DC generator/Genset output current/voltage and the diesel motor/engine, the rechargeable batteries voltage, the generator /Genset electrical power (measured in Killo-Watts, KW), the motor RPM (Rounds/cycles Per Minute), the temperature of the diesel engine/motor cooling water and the oil pressure magnitude.

In yet another embodiment of the present invention, the battery bank comprises a plurality of Lithium-Iron (Li-Fe) rechargeable batteries.

In yet another embodiment, the DC current supply generator/Genset is stabilized in a relatively short period of time to a certain target value of high DC supply current of between 500 and 1000 A (A = Ampere), wherein stabilization locking response of the generator's current comprises a preliminary ramp current value accompanied by a further stabilization of the current magnitude value, which is reduced linearly to zero value close to charge completion of the plurality of batteries.

In yet a further embodiment, the hybrid, high power generator system is embedded inside an isolated closed platform and easily moved between locations. It has a full electrical and acoustical isolation during its operational stage.

In a further embodiment, the present invention discloses a system, which can be configured to supply a single or three phase current-voltage source as required by the application.

In a further embodiment, the Genset controller provides resources for 16 additional digital inputs and 16 additional digital outputs, wherein the digital inputs can be extended using a digital input extension module, wherein the input and output extension modules are connected to the main Genset controller in a cascade structure, in any required order. The connection cable is provided with each extension module.

In a further embodiment, the system further comprises an extension input, providing a plurality of inputs. In a particular embodiment, the extension module type is an OR – 188. In this case, digital inputs are programmable through the main Genset controller.

The switching characteristic can not be programmable. In another embodiment, the switching characteristics are programmable. In a further embodiment, a function selected from a set of functions can be assigned to a single or plurality of digital 6 inputs. In yet a further embodiment, the digital outputs can be extended using OR - 186 Fet Extension modules, wherein each one provides eight outputs. In this setup, the digital outputs have the same electrical characteristics as on board outputs. In yet a further embodiment, a plurality of programmable functions can be assigned through the main Genset controller, wherein any of these functions can be assigned to any dedicated output terminals of the Genset controller.

In another embodiment, the hybrid, high power generator system comprises: - a driving engine with electro-mechanical coupling means with a DC high power current supply generator/Genset through mechanical and electrical input interface means, with at least one electrical input interface for external control and regulation of the Engine RPM with an external control means, with at least one monitoring means for engine condition such as the engine temperature, fuel and oil levels, oil pressure and temperature, coolant liquid level and temperature, engine battery and coils functional conditions; - a battery bank comprising a plurality of rechargeable batteries with an electrical charging means with an external controlled interface and electrical monitoring interface means; - a high power DC current supply generator (labelled as Genset) that comprises an alternator module; a current supply module and an electro-mechanical coupling interface means with the external driving engine with an electrical charging interface means with at least one electrical control interface means with the battery bank, wherein the current supply generator/Genset further comprising at least one electrical monitoring input interface means for the output voltage and charging current of the generator/Genset and at least one electrical input interface for regulation of the output voltage and charging current values of the generator/Genset; - a plurality of electrical voltage and current interconnection lines and a plurality of data interconnection lines; - a Genset controller with an interface monitoring and sensing means with the generator/Genset, with the driving engine and with the battery bank, wherein the Genset controller further comprising an electrical control interface means for control of the generator/Genset output voltage and related charging current of the 7 battery bank and the generator/Genset, wherein the Genset controller further comprising at least one switching and actuation means for controlling the connection between the generator/Genset and the driving engine and the generator/Genset and the plurality of rechargeable batteries, wherein the Genset controller is connected through a plurality of the electrical and data interconnection lines to the interface means of the generator/Genset, the interface means of the diesel driving engine and the interface means of the battery bank, wherein the Genset controller senses and monitors the supply voltage of the battery and launches a charging cycle of the plurality of rechargeable of batteries when it senses that it drops below pre-defined threshold values.

During a charging phase cycle of the plurality of rechargeable batteries or during an idle phase, the Genset controller utilizes its electrical actuating and switching means to disconnect and regulate the output voltage and charging current of the generator/Genset with the plurality of rechargeable batteries, the RPM of the driving engine and sensing and monitoring the generator/Genset voltage. Per predefined conditions of the engine RPM and generator/Genset voltage, it toggles the at least one switching and actuation means for an optimal charging of the rechargeable batteries and minimizing the charging process power loss and charging time of the generator/Genset by the driving engine.

Particularly, the engine RPM determines the strength of magnetic field induced in the rotor of the generator. As the RPM increases magnetic torque increases and the resistance of the magnets/electromagnets as well to the developing magnetic field. To reduce this resistance effect, in one embodiment, the engine may be operated at relatively low RPM, where synchronization with the frequency of the grid is done in a further step. Further, relatively low fixed work RPM, such as 1,500 RPM elected for the particular system of the present invention, may optimize the system operation, because it is sufficient to output current to charge the batteries in a short time, economic in fuel consumption and prolongs the engine’s life.

In still a further embodiment, the at least one switching and actuation means of the Genset controller comprises a load contactor, electrically connected to a related 8 switch, which is toggled between short and open states, further enabling or disabling a charging of the plurality of rechargeable batteries by the generator/Genset.

In still a further embodiment, the load contactor voltage and common terminals are connected to an electrical switch, which is electrically controlled by the Genset controller and can be toggled between "open" and "short" states. The load contactor terminals are electrically connected to the electrical switch between the generator/Genset and the battery bank and can be electrically disconnected between the generator/Genset and the battery bank. In still a further embodiment of the present invention, the load contactor is electrically connected to a DC load contactor through its electrical switch, wherein in its "open state" the AC/DC generator is toggled to a standby power state and is electrically connected to the DC load. In still a further embodiment, the load contactor is toggled by the Genset controller into an "Open" state when the generator is at idle state, when the Genset controller monitoring a certain threshold voltage value on the plurality of rechargeable batteries, which indicate full charging state of the plurality of rechargeable batteries. In a further embodiment of the present invention, the DC load electrical unit is connected to the DC generator also in its closed state, enabling it to monitor the applied voltage on the plurality of rechargeable batteries. In yet a further embodiment, the Genset generator and particularly the DC alternator load output terminals are connected to the negative and positive DC alternator output voltage, which are connected to the DC load positive terminal. In this case, the polarity must be correct and the supply of current values, which must not be larger than a threshold value to avoid the unit to display faulty current measurements and corresponding damage to the unit or the connected load. In one particular embodiment, the DC load is a 24V/48 DC load.

In still a further embodiment, the alternator voltage matches the voltage of the battery bank. The switch will be toggled from open to short states, enabling the load contactor output device to be energized.

In still a further embodiment, the supply generator further comprises an AC current supply generator and an AC to DC modification and regulation units. 9 In still a further embodiment, the Genset controller monitors the generator/Genset input/output voltages of the battery bank, the Generator/Genset electrical power (measured in Killo-Watts, KW), the motor RPM (Rounds/cycles Per Minute), the diesel engine/motor cooling water temperature and the oil pressure magnitude.

In still a further embodiment, the hybrid, high power generator system further comprises a 12 power bar connection unit which is connected to all of the system components with electrical input and output lines on one side and to data and electrical input/output interface of the Genset controller on the other side. The Genset controller unit utilizes the 12 power-bar switch control unit for optimal distribution of the charging current via the electrical lines to a corresponding plurality of rechargeable batteries.

In still a further embodiment, the Genset controller is connected to the 12 power bar and switch control unit via a wire or wireless WiFi, Bluetooth or other wireless control means, which comprises wireless network hardware, software and communication protocols. The Genset controller controls all of the related components of the hybrid high power current/voltage generator system through the 12 power bar electrical connection unit.

In still a further embodiment, the generator/Genset controller is connected to the 12 power bar connection unit via wireless data WiFi, Bluetooth or other wireless control means, wherein the Genset controller utilizes wire or wireless communication protocols and network software and hardware means and corresponding communication and control protocols.

In still a further embodiment, each of the electrical charging lines are connected to the 12 power bar connection unit on one side and the plurality of rechargeable batteries on the other side through a plurality of latching relay units, which are controlled by the Genset controller. The control means further comprises additional data control lines for monitoring and remote controlling the plurality of relay units.

In still a further embodiment, each of the electrical charging lines is connected to the electrical DC generator/Genset on one side and the rechargeable bank of batteries on the other side through at last one latching relay 24/500A units. The latching relay 24/500A further comprises monitoring means for the charging process parameters of the plurality of rechargeable batteries such as monitoring the charging current, voltage and charging level of the plurality of batteries. The plurality of latching relay 24/500A units can be toggled between open and short states and start and stop the electrical charging current of the electrically attached plurality of rechargeable batteries.

In still a further embodiment, the Genset controller monitoring means is connected to the electrical input/output interface monitoring means of the generator/Genset, the diesel driving engine and the plurality of rechargeable batteries, and executes some of the following measurements: The electrical Genset power factor; engine rpm, oil pressure and temperature; engine coolant temperature, fuel level; batteries' voltage: mains phase voltages L1,-L2,-L3, mains frequencies: digital input statuses: charge input status; J1939 values (if applicable); event number: event type/fault definition, date and time, operation mode: operation status (on-load, on-mains, cranking, etc...): alternator DC voltage; battery bank DC voltage; alternator DC current; Genset controller active power (kW); battery bank temperature; oil pressure; engine temperature; fuel level, oil temperature; canopy temperature; ambient temperature; engine rpm; battery voltage; internal temperature of charge voltage module, driver demand engine percentage torque and actual engine percentage torque in its coupled and uncoupled mode to the generator/Genset.

In still a further embodiment, the generator/Genset is stabilized in relatively short period of time to a certain target value of high DC supply current of about 100-1000 A. In another embodiment, the stabilization locking response of the generator's current comprises a preliminary ramp current response value accompanied by a further stabilization of the current magnitude value.

In still a further embodiment, the plurality of rechargeable batteries are connected to a plurality of 24/240 V electrical adaptors through a master bus network, type Combi pro 24/3500 100 (230V), wherein the electrical adaptors are connected to AC-IN and AC load lines respectively, feeding a plurality of electrically connected loads. 11 In still a further embodiment, the electrical adaptors are connected to a multipurpose contact output and easy view screen through a master bus USB interface unit.

In still a further embodiment, an easy view screen enables to monitor and supervise the performance and status of the hybrid high power current/voltage generator system, this includes monitoring and supervising of the charging condition of the rechargeable batteries, the available power of the generator/Genset voltage supply system and the required electrical power by the plurality of connected loads. The master-bus USB interface unit further enables to externally control the hybrid high power current/voltage generator system, identifying problems, malfunctions and errors and executing troubleshooting protocols. The multipurpose contact unit output enables to supervise the condition of the system through other interface view means.

In still a further embodiment, the Genset controller further comprises a control panel comprising the following buttons: a run mode or a stop button; an auto mode button; a stop mode button; an alarm mute button and corresponding indicator units, and a plurality of LED condition indicator units such as a service request indicator, a fault condition indicator, an LCD Graphic LCD screen indicator, a mimic diagram on system status, a shut down alarm indicator, a warning indicator, a service request indicator, a test mode indicator, a run mode indicator, auto mode indicator, a STOP mode indicator, a Genset indicator, a load contactor indicator.

In still a further embodiment, the Genset controller is designed with the following features: Compatible with 12V, 24V and 48V DC systems; a DC power drive output (7A-DC); an ECU connection through J1939 CAN option 0-10V analog control output isolated Volt - Amp measurements; a battery temperature input for PT100 sensor; an optimal charging that provides longer battery life temperature dependent battery charging level; a thermal protection, short circuit protection and a dual Genset mutual standby operation with a plurality of event logs with time stamp and measurements; a battery backed-up real time clock; a built in daily/weekly/monthly exerciser; field adjustable parameters; an RS-232 serial port; a Free MS-Windows 12 Remote monitoring SW GSM and PSTN modem support GSM SMS message sending on fault MODBUS communications; multiple language support and customer logo display capability.

In still a further embodiment, the electrical circuit of the Genset controller further comprises a positive/negative current measurement input for measuring the outputs of the current shunt resistor, which are connected to these terminals. The current measurement circuit is isolated from the rest of the device, wherein the current shunt may be placed in a positive or a negative branch of the alternator without affecting the measurement quality.

In still a further embodiment, the Genset controller further comprises negative and positive DC input terminals for electrical connection with the alternator input voltages and DC load positive and negative terminals.

In still a further embodiment, the Genset controller electrical circuit further comprises temperature measurements input terminals, which are connected to the temperature sensor input of the battery bank. Related temperature sensors are used by the Gesnset controller unit to protect the battery bank from overheating during a charging cycle.

In still a further embodiment, the Genset controller electrical circuit further comprises two actuator plus/minus output terminals with a current range and a maximum value, wherein the actuator plus/minus outputs can be increased by the Genset controller in order to supply more fuel to the driving engine.

In still a further embodiment, the Genset controller electrical circuit further comprises a short protection circuit.

In still a further embodiment, the Genset controller electrical circuit further comprises a +12/24 VDC battery positive and negative voltage terminals, enabling the power supply unit to operate on both +12V and +24V battery systems. 13 In still a further embodiment, the Genset controller is configured to indicate on various types of "alarm" and stop or modification of certain process of the system, indicating threshold values of the system.

In still a further embodiment, a hybrid, high power generator system is embedded inside an isolated closed platform and easily moved between locations. The closed platform further comprises a full electrical and acoustical isolation during its operational stage, wherein the system provides maximum versatility and is able to operate in various outdoor locations at different environments and weathers, and temperature and humidity various conditions.

In still a further embodiment of the generator system, a Max Charge Time parameter is provided as a measure of the plurality of batteries charging conditions. When the Genset controller detects precisely the end-of-charge condition, it will stop the engine before the expiration of the Max Charge Time parameter, which corresponds to the charging level of the rechargeable batteries, providing an optimal fuel economy and a longer service life.

In still a further embodiment, the generator system can be configured to supply a single or three phase current-voltage source as required by the application.

APPARATUS: In one preferred embodiment of the present invention, The Genset controller is labeled as OR379 which has been developed with particular disclosed preferences.

The Genset controller unit has been designed for sensing, monitoring, controlling and actuating of the Hybrid High Power generator of the present invention, as specified in the following Sections I-XXII and at the detailed description in Figs. 2 and 4A-C.

I. GENSET CONTROLLER MEASUREMENTS In one preferred embodiment, the Genset controller can execute the following measurements: The genset power factor; the engine rpm; the oil pressure and temperature; the coolant temperature, fuel level: battery voltage: mains phase voltages labeled as L1-L2-L3, mains frequencies: digital input statuses: charge input status J1939 Values (if 14 applicable) event number: event type/fault definition, date and time, operation mode: operation status (on-load, on-mains, cranking, etc...): alternator voltage DC; battery bank voltage D; alternator current DC; Genset controller active power (kW); battery bank temperature; oil pressure; engine temperature; fuel level, oil temperature; canopy temperature; ambient temperature engine rpm; battery voltage; charge voltage module internal temperature, the driver demand engine percentage torque and the actual engine percentage torque in its coupled and uncoupled mode to the Genset/DC current generator.

II. GESET controller Event sources are - Shutdown alarms, load dump alarms, warnings - Periodic records. event logs displayed within the program mode menu. The above is designed to reduce the interference of event logs with other measurement screens.

III. GENSET CONTROLLER STATISTICAL COUNTERS The unit provides a set of non-resettable incremental counters for statistical purposes.

The counters consist of - Total Genset kWh; - Total engine hours; - Total engine cranks; - Total engine runs; - Engine hours to service; - Time to service.

V. GENSET CONTROLLER MANUAL OPERATION AND MAIN BUTTONS: - Stopping the engine; - Starting the engine; - Manual load transfer. Genset will run with the connected load; - Automatic operation.

IV. GENSET CONTROLLER STOP MODE In this mode, the Genset will be in a rest state.

- The STOP mode is manually entered by pressing the related button; - When a STOP mode is selected, if the Genset is running under load, then it will be immediately unloaded. The engine will continue to run during cool-down according to a timer and will stop afterwards.

- If the STOP button is pressed again, then the engine will immediately stop.

- If the engine fails to stop after the expiration of Stop Timer then a “Fail to Stop” warning will occur.

- If a “Remote Start” or “Force to Start” signal arrives in a STOP mode, the Genset will not start until AUTO mode is selected.

V. GENSET CONTROLLER AUTO MODE - The AUTO mode is entered manually by pressing the related button.

- The AUTO mode is used for the automatic charging of the battery bank. The Genset controller will constantly monitor the battery bank voltage. It will run the engine and transfer the load when the voltage falls below programmed threshold.

The mains availability evaluation sequence is detailed below: • If the battery bank voltage is below threshold, this will generate an engine start request.

• If a “Simulate Mains” signal is present, then the engine start request is reset.

• If a “Force to Start” signal is present, then this will generate an engine start request.

• If a “Remote Start” input is defined, then this signal decides of the engine start request.

When an “engine start request” occurs, the engine start sequence begins: • The unit waits during Engine Start Delay for skipping erroneous engine start requests. If the engine start request is reset before the end of this timer, the Genset will not start.

• The unit turns on the fuel and preheat glow plugs (if any) and waits for preheat timer.

• The engine will be cranked for programmed times during crank timer. When the engine fires, the crank relay is immediately deactivated.

• The engine will run at idle speed during Idle Speed Timer.

• The engine will run unloaded during engine heating timer.

• The engine will be accelerated smoothly until the alternator voltage matches the battery bank voltage. Then the load contactor output will be energized. 16 When the battery charging cycle ends, an engine stop sequence begins: • The Genset controller decreases the rpm until charge current becomes zero.

• Then the load contactor is deactivated.

• The Genset controller decreases the rpm until idle speed.

• If a cooldown period is given, the generator/Genset will continue to run at idle speed during the cooldown period.

• At the end of cooldown, the fuel solenoid will be de-energized, the stop solenoid will be energized for Stop Solenoid timer and the diesel will stop.

• The Genset controller will wait until the battery voltage falls below the Genset startup voltage VI. GENSET CONTROLLER RUN MODE, MANUAL CONTROL BUTTONS The RUN mode is entered by manually pressing the button. When the RUN mode is selected, the engine will be immediately started.

The starting sequence is as described below: The unit turns on the fuel and preheat glow plugs (if any) and waits for preheat timer.

• The engine will be cranked for programmed times during crank timer. When the engine fires, the crank relay is be immediately deactivated.

• The engine will run at idle speed during Idle Speed Timer.

• The engine will run unloaded until another mode is selected.

VII. GENSET CONTROLLER TEST MODE The TEST mode is used in order to test the Genset under load. Once this mode is selected, the engine will run as described in the AUTO mode, regardless of the battery bank voltage and a charging cycle will be initiated.

When the charging cycle is terminated, the Genset will run at a speed to establish the “nominal charge voltage” and will feed the load indefinitely unless another mode is selected.

The unit decides with precision the moment to run the Genset and performs a high efficiency charging cycle. The complete charging cycle will always include a float charge cycle. Following programming, a boost charging cycle may be added. The maximum charge duration is limited with parameter “Max Charge Time”. Following 17 the value of the parameter “Stop Current percent”, the Genset controller will detect precisely the end-of-charge condition and will stop the engine before the expiration of the Max Charge Time parameter, providing fuel economy and longer service life.

The unit decides with precision the moment to run the Genset and performs a high efficiency charging cycle. The complete charging cycle will always include a float charge cycle. Following programming, a boost charging cycle may be added. The maximum charge duration is limited with parameter “Max Charge Time”. Following the value of the parameter “Stop Current percent”, the Genset controller will detect precisely the end-of-charge condition and will stop the engine before the expiration of the Max Charge Time parameter, providing fuel economy and longer service life.

VIII. GENSET CONTROLLER PARAMETERS Start to Charge Voltage: 24.0 Volts When the battery bank voltage falls below this level, then the Genset controller will initiate an automatic charging cycle. The default value is set for a 24V battery bank.

Max Charge Current: 50 Ampere.

This is the maximum allowed charge current flowing from the alternator to the battery bank.

Max Charge Time: 120 minutes This is the maximum duration of a charge cycle. Even if the charge cycle is not completed at the expiration of this timer, the engine will stop.

Nominal Charge Volt: 27.4 Volts This is the float charge voltage of the battery bank. The default value is set for a 24 Volts battery bank.

Max Battery Temperature: 90°C This is the maximum allowed temperature of the battery bank. If the temperature approaches this limit, then the charging current will be reduced.

Boost Enable: "0" or "1" modes. 0 mode: No boost charge cycle; 1 mode : Boost charge cycle is performed. The charge voltage will be set to the nominal boost voltage during boost execution time.

Boost Start Current: 30% 18 If the boost charge is enabled, when the charge current goes below this percentage of the max charge current, then the boost charge cycle will be initiated.

Boost Execution Time: 3 minutes If enabled, the boost charge is performed during this timer.

Nominal Boost Voltage: 28.8 V This is the max charging voltage allowed during the boost cycle.

IX. BATTERY VOLTAGE INPUT Supply voltage: 9 to 33 VDC.

Cranking dropouts: Survives 0 VDC during 100ms. The voltage before surge should be 9VDC minimum.

Overvoltage protection: Withstands 150VDC continuously.

Reverse voltage: -33VDC continuous mode.

Maximum operating current: 250mA @ 12/24VDC (All options included, digital outputs open.).

Typical operating current: 200mA @ 12/24VDC (all options passive, digital outputs open).

Measurement range: 0 to 36VDC.

Display resolution: 0.1VDC.

Accuracy: .0.5% + 1 digit @ 24VDC.

X. GENSET MODES: The GENSET unit provides 3 different protection levels, being warnings, load-dumps and shutdown alarms: 1. SHUTDOWN ALARMS: These are the most important fault conditions and cause: - The ALARM led to turn on steadily; - The load contactor to be released immediately; - The engine to be stopped immediately, - The Alarm digital output to operate. 2. LOAD DUMPS: These fault conditions come from electrical trips and cause: - The ALARM led to turn on steadily; - The load contactor to be released immediately; 19 - The engine to be stopped after a cooldown period; - The alarm digital output to operate. 3. WARNINGS: These conditions cause: - The WARNING led to turn on steadily; - The Alarm digital output to operate.

Alarms operate in a first occurring basis: If a shutdown alarm is present, following shutdown alarms, load dumps and warnings will not be accepted.

If a load dump is present, following load dumps and warnings will not be accepted.

If a warning is present, following warnings will not be accepted.

XI. WARNINGS ALARM TYPES Alarms may be of LATCHING type following programming. For latching alarms, even if the alarm condition is removed, the alarms will stay on and disable the operation of the Genset. Most of the alarms have programmable trip levels. These conditions cause by the following Warning Types: A. SHUTDOWN ALARM GENSET LOW/ HIGH SPEED: Set if the engine rpm is outside programmed limits. These faults will be monitored with Holdoff Timer delay after the engine is running. Low and high limits for warning and alarm are separately programmable.

Another high engine rpm shutdown limit which is 12% above the high limit is always monitored and stops the engine immediately.

GENSET HIGH VOLTAGE: Set if the battery bank DC voltage goes over the programmed limit for Overload Timer. This fault will be monitored with holdoff timer delay after the engine is running.

HIGH BATTERY VOLTAGE: Set if the battery voltage goes above programmed limits. Both warning and alarm levels for high battery voltage are programmable.

FAIL TO START: Set if the engine is not running after programmed number of start attempts.

J1939 ECU FAIL: Set when an engine fault code is received from the ECU of the electronic engine. This fault will not cause an engine stop. If necessary, the engine will be stopped by the ECU.

LOW OIL PRESSURE: Set if a signal is detected at the Low Oil Pressure Switch input or the oil pressure value measured from the sender is below the programmed limit. Warning and alarm limits are separately programmable for the oil pressure sender input. This fault will be monitored with Holdoff Timer delay after the engine is running. Also if the oil pressure switch is open at the beginning of a start attempt, then the engine will not be started and “Oil Pressure Exists!” information is displayed.

When the oil pressure switch closes, normal operation will be resumed.

HIGH TEMPERATURE: Set if a signal is detected at the High Temperature Switch input or the coolant temperature value measured from the sender is above the programmed limit. Warning and alarm limits are separately programmable for the temperature sender input.

LOW TEMPERATURE: Set if the coolant temperature value measured from the sender is blow the Engine Heating Temperature limit.

LOW FUEL: Set if a signal is detected at the low fuel level input or the fuel level measured from the sender is below the programmed limit. Warning and alarm limits are separately programmable for the fuel level sender input.

EMERGENCY STOP: Set if a signal is detected at the emergency stop input.

SPARE-1 / SPARE-2: Set if a signal is detected from the related spare fault input.

B. LOADDUMP ALARMS: * The system uses 24 DC load and load contactor. 21 OVERLOAD: Set if the alternator output current goes over the Overcurrent Limit for Overload Timer. If the current goes below the limit before expiration of the timer then no alarm will be set.

EXCESS POWER: Set if the Genset power (KW) supplied to the load goes over the Excess Power limit for Overload Timer. If the power goes below the limit before expiration of the timer then no-alarm will be set.

C. GENERAL ALARMS GENSET LOW / HIGH SPEED Set if the engine rpm is outside programmed limits. These faults will be monitored with Holdoff Timer delay after the engine is running. Low and high limits for warning and alarm are separately programmable. Another high engine rpm shutdown limit which is 12% above the high limit is always monitored and stops the engine immediately.

* The system uses 24 DC load and load contactor GENSET LOW / HIGH VOLTAGE: Set if the battery bank DC voltage goes outside programmed limits for Overload Timer. This fault will be monitored with holdoff timer delay after the engine is running.

LOW / HIGH BATTERY VOLTAGE: Set if the Genset battery voltage is outside programmed limits. FAIL TO STOP set if the engine has not stopped before the expiration of the Stop Timer.

LOW CHARGE VOLTAGE: Set if a charge alternator failure (or broken belt) occurs. This fault condition may result to a warning or alarm following programming.

J1939 ECU FAIL: Set when an engine fault code is received from the ECU of the electronic engine. This fault will not cause an engine stop. If necessary, the engine will be stopped by the ECU. 22 LOW OIL PRESSURE: Set if a signal is detected at the Low Oil Pressure Switch input or the oil pressure value measured from the sender is below the programmed limit. Warning and alarm limits are separately programmable for the oil pressure sender input. This fault will be monitored with Holdoff Timer delay after the engine is running. Also if the oil pressure switch is open at the beginning of a start attempt, then the engine will not be started and “Oil Pressure Exists!” information is displayed.

When the oil pressure switch closes, normal operation will be resumed.

HIGH TEMPERATURE: Set if a signal is detected at the High Temperature Switch input or the coolant temperature value measured from the sender is above the programmed limit. Warning and alarm limits are separately programmable for the temperature sender input.

LOW TEMPERATURE: Set if the coolant temperature value measured from the sender is below the Engine Heating Temperature limit.

LOW FUEL: Set if a signal is detected at the low fuel level input or the fuel level measured from the sender is below the programmed limit. Warning and alarm limits are separately programmable for the fuel level sender input.

EMERGENCY STOP: Set if a signal is detected at the emergency stop input.

SPARE-1 / SPARE-2: Set if a signal is detected from the related spare fault input.

SERVICE REQUEST: Set if the service counter has expired. In order to reset the service counters, hold pressed both with buttons during 5 seconds. The screen will display “Completed!” SHORT CIRCUIT PROTECTION ACTIVE: Set if the actuator output is short circuited or overloaded. When the short circuit is removed, the unit will automatically revert to normal operation. However this warning will persist and must be reset manually. 23 SERVICE REQUEST: Set if the service counter has expired. In order to reset the service counters please hold pressed both with buttons during 5 seconds. The screen will display “Completed!”.

SHORT CIRCUIT PROTECTION ACTIVE: Set if the actuator output is short circuited or overloaded. When the short circuit is removed, the unit will automatically revert to normal operation. However this warning will persist and must be reset manually.

XII. WARNINGS ALARM SIGNALS - The WARNING led to turn on steadily; - The Alarm digital output to operate.

XIII. BATTERY BANK DC VOLTAGE INPUTS Measurement method: Isolated DC voltage measurement Sampling rate: 100K s/s Input voltage range: 0 to 70 VDC Measurement range: 0 to 70VDC Input impedance: 215 K-ohms Display resolution: 0.1VDC Isolation: 500VAC, 1 minute Accuracy: 0.5% + 1 digit (±0.35V@50VDC) XIV. BATTERY BANK CHARGE CURRENT INPUT Measurement method: Isolated DC voltage measurement Sampling rate: 100 Ks/s Input voltage range: 0 to 100 mVDC Measurement range: 0 to 100 mVDC Input impedance: 1000 ohms Isolation: 500VAC, 1 minute Accuracy: 0.5% + 1 digit (±0.6A@100ADC) Current shunt range: 1A/60mV to 5000A/60mV Display resolution: 0.1ADC (shunt < 250A/60mV) 1ADC (shunt > 250A/60mV) 24 XV. DIGITAL INPUTS Number of inputs: 7 inputs, all configurable Function selection: from list Contact type: Normally open or normally closed (programmable) Switching: Battery negative or battery positive (programmable) Structure: 47 k-ohms resistor to battery positive, 110 k-ohms to battery negative Measurement: Analog voltage measurement Open circuit voltage: 70% of battery voltage Low level threshold: 35% of battery voltage High level threshold: 85% of battery voltage Maximum input voltage: +100VDC with respect to battery negative Minimum input voltage: -70VDC with respect to battery negative Noise filtering: yes XVI. ANALOG SENDER INPUTS AND SENDER GROUND Number of inputs: 4 inputs, with configurable curve Structure: 667 ohms resistor polarizing to 3.3 VDC Measurement: Analog resistor measurement Open circuit voltage: +3.3 VDC Short circuit current: 5 mA Measurement range: 0 to 5000 ohms Open circuit threshold: 5000 ohms Resolution: 1 ohms @ 300 ohms or lower Accuracy: 2 % + 1 ohm (±7 ohms @300 ohms) Noise filtering: yes XVII. CHARGE INPUT TERMINAL The Charge terminal is both an input and output. When the engine is ready to run, this terminal supplies the excitation current to the charge alternator. The excitation circuit is equivalent to a 2W lamp. The threshold voltages for warning and shutdown alarm are adjustable through program parameter.

Structure: • battery voltage output through 20 ohm PTC. • voltage measurement input.

Output current: 160 mA @ 12 VDC, 80 mA @ 24 VDC.

Voltage measurement resolution: 0.1VDC.

Voltage measurement accuracy: 2% + 0.1V (0.9V @ 30 VDC).

Charge Fail Warning Threshold: adjustable.

Charge Fail Shutdown Alarm Threshold: adjustable.

Open circuit voltage: battery positive.

Overvoltage protection: > 500 VDC continuous, with respect to battery negative.

Reverse voltage protection: -30VDC with respect to battery negative.

XVIII. DIGITAL OUTPUT The unit offers four digital outputs. Fuel and crank relays have fixed function. Other two relays have programmable function, selectable from list.

Structure: Negative pulling protected semiconductor output. One terminal is connected to battery negative.

Max continuous current: 1.0 ADC.

Max switching voltage: 33 VDC.

Overvoltage protection: 40 VDC.

Short circuit protection: > 1.7 ADC.

Reverse voltage protection: 500 VDC.

XIX. LOAD CONTACTOR OUTPUT * The system uses 24 DC load and load contactor Structure: Relay output, normally open contact. Both terminals provided.

Max switching current: 16A @ 250 VAC/30 VDC.

Max switching power: 4000 VA.

XX. ANALOG OUTPUT Structure: linear output for rpm/voltage control.

Functionality: Precision PID control output, regulating rpm/voltage for voltage matching, current control, temperature and rpm limiting. 26 Output impedance: 1 k-ohms.

Output voltage: 0-10 V-DC.

Frequency range: 10Hz to 10 kHz.

Resolution: 0.1%.

Accepted Load: > 10 k-ohms.

XX. MAGNETIC PICKUP INPUT Structure: Differential frequency measurement input, MPU or charging pulses.

Input impedance: 100 k-ohms.

Input voltage: 1.0 VAC-RMS to 100 VAC-RMS.

Frequency range: 10Hz to 10 kHz.

Resolution: 1 rpm.

Accuracy: 0.2% + 1 rpm (±3rpm @1500 rpm).

Flywheel teeth range: 1 to 500 DCV.

XXI. J1939-CANBUS PORT Structure: CANBUS, non-isolated.

Connection: 3 wires (CANH-CANL-GND).

Data rate: 250 kbps.

Termination: Internal 120 ohms provided.

Common mode voltage: -0.5 VDC to +15 VDC, internally clamped by transient suppressors.

Max distance: 200 m with 120 ohm balanced cable.

XXII. Genset controller (OR -379) DC Supply Range: 9.0 to 33.0 V-DC Cranking dropouts: survives 0 V for 100 ms.

Typical Standby Current: 200 mA-DC, Maximum Operating Current: 250 mA-DC (outputs open).

Load Contactor Relay Output: 16 A / 250V-AC / 30VDC DC Outputs: 1A @ 28V protected semiconductor outputs Charge excitation: min 2 Watts Analog Output: Output Range: 0-10 V-DC.

Output Impedance: 1K-ohms, Max Load: 10 K-ohms, Digital Inputs: 0 to 33V-DC 27 Analog sender input range: 0-5000 ohms. Battery Temp. Input: standard PT100 sensor.

Magnetic pickup input: 1.0 – 100VAC-RMS.

Magnetic pickup frequency: 10 KHz max. Alternator voltage: 0 to 70 V-DC Battery.

Bank voltage: 0 to 70 V-DC, Current input: from DC shunt, 60 mV at rated current.

Rated Current range: 1 to 5000 ADC at 60mV, Actuator Output Voltage: 0 to 12/24V.

Actuator Drive: 7 A-DC max, current limited, short circuit and thermally protected.

Actuator Short Circuit Protection: min 9 Amp Serial port: RS-232, 9600 bauds, no parity, 1 bit stop Operating temp.: -20°C (-4°F) to 70°C (158°F). Storage temp.: - 40°C (-40°F) to 80°C (176°F). Maximum humidity: 95% non-condensing.

Dimensions: 172 x 134 x 76 mm (WxHxD), Panel Cut-out Dimensions: 151x111 mm minimum. Weight: 450 g (approx.), Case Material: High Temperature ABS/PC (UL94-V0), IP Protection: IP65 from front panel, IP30 from the rear CE Conformity reference standards: EN 61010 (safety requirements) EN 61326 (EMC requirements).

Method In one embodiment of the present invention, a charging method of charging a plurality of rechargeable batteries is provided, wherein this method comprises: - providing a plurality of power supply rechargeable batteries, a DC output voltage generator/Genset that comprises an alternator and a AC to DC converter, a load contactor connected to a switch, wherein the load contactor voltages and common terminals are interconnected between the DC generator/Genset and the plurality of rechargeable batteries. - providing monitoring means for each of the plurality of the batteries voltage, the DC generator/Genset voltage, the Engine rpm, the charge current; - initiating a charging process of the plurality of rechargeable batteries that comprises a sequence of steps in an optimal charging sequence. Such sequence is selected from different recharging sequences, which are detailed in the following description. In all these sequences, the Genset Controller controls the generator and forces it to output constant current at selected value. The Genset controller 28 controls the current output from the stator by controlling the applied voltage on the rotor.

Commonly, a voltage regulator in the generator regulates the magnetic flux in the rotor and the current induced in the stator to eventually regulate the output current to a load. Accordingly, the voltage regulator monitors and controls the voltage on the rotor to match a preset output voltage. Recharging a battery bank with a standard generator will, therefore, respond to the gradual increase in resistance in the recharging batteries, which will reduce the generator output current and result in long time of recharging. To shorten the recharging time in the present invention, a modification in the generator includes removing the voltage regulator and introducing the Genset controller. This controller is placed on the stator part and applies voltage on the rotor to force the generator to output current at constant selected value until complete recharging of the battery bank, namely the load connected to the generator. Outputting constant current significantly reduces recharging time of the batteries despite the resistance to charging build-up in the batteries. However, such modification in the generator and corresponding recharging regime requires continuous monitoring of the system operation to ensure that proper conditions are kept, e.g., temperature, oil pressure, voltage leveling between the generator output and battery bank.

When recharging batteries with a standard generator, increases resistance to charging of the load, namely the battery bank, will take significantly longer time to recharge the battery bank than the modified generator and corresponding method in the present invention. The Genset controller ensures the integrity of this recharging system during recharging and safe completion of the recharging process by continuously monitoring the parameters of the different components of the system and keeping them within acceptable working ranges. The Genset controller controls the DC voltage in the generator by controlling the part in the generator that applies voltage on the rotor.

Such part may be slip rings or brushes or an induction coil and diodes. Both may take current from the stator or the batteries in the battery bank to produce the applied voltage on the rotor. 29 In a further embodiment of the present invention the charging method of the hybrid power supply generator is provided, wherein the charging process comprises the following sequence of steps in an uncontrolled charging sequence: - Step A: The Genset is at rest. The electrically attached load consumes power from the battery bank. The battery bank voltage decreases slowly with discharge level.

When the battery bank voltage falls below the certain defined start to charge voltage, after the charge voltage threshold timer step is done, the Genset controller detects that the battery bank is at a discharged state and decides to run the Genset.

- Step B: The engine is started, the Genset output voltage increases with the Engine rpm increase. The Genset controller adjusts the Engine rpm in order to match exactly the battery bank voltage. When voltage matching is reached, the load contactor is closed. Thus load contactor switching is performed with zero current.

This provides longer contactor life.

- Step C: The controller increases the Engine rpm until reaching the maximum value for the charging current which sharp increase to its preset value.

- Step D: The Engine rpm is controlled and increased in order to keep the Charge current at a constant value/state, at its maximum preset value. The battery bank voltage increases slowly until reaching the nominal charge voltage.

- Step E: The Engine rpm is controlled in order to keep the battery bank voltage at the nominal charging voltage, wherein charge current decreases slowly during this step.

- Step F: When the charge current falls below the boost-start current, the Genset controller starts the optional boost charge cycle. At the start of the optional boost charge cycle, the Genset controller re-boosts the charging current by an increase of the Engine rpm and a corresponding sharp increase of the charge current.

- Step G: The maximum charging current is maintained at its maximum constant value until the battery voltage reaches the nominal boost voltage. The Genset controller increases the Engine rpm slowly until reaching the maximum charging current. The battery bank voltage increases slightly with charge percentage.

- Step H: The rpm is controlled in order to keep the battery bank voltage at nominal boost voltage. The charge current decreases slowly.

- Step J: When the charge current falls below the stop current percent, the Genset controller decreases the Engine rpm until the charge current reaches a zero value, then opens the load contactor and decreases the Engine rpm until idle speed.

- Step K: The idle speed is kept constant until the end of cooldown period.

- Step L: The engine comes to rest. The load consumes power from the battery bank. The battery bank voltage decreases slowly with discharge level. The Genset controller waits until the battery bank voltage falls below the start of a new charge voltage, to restart a new charging cycle and a new charging sequence is repeated.

In another embodiment, the charging method of the hybrid power supply generator is provided, wherein the charging process comprises the following sequence of steps in an uncontrolled charging sequence: - Step_A: The Genset is at rest. The load consumes power from the battery bank, the battery bank voltage decreases slowly with discharge level, when the battery bank voltage falls below the start to charge voltage, after the charge voltage threshold timer, the Genset controller detects that the battery bank is discharged and decides to run the Genset.

- Step_B: The engine is restarted with the Genset controller. The Genset output voltage drives to increase Engine rpm which increases driving a subsequent increase of the Genset voltage.

- Step_C: After completion of the Genset Contactor Timer, the load contactor is toggled by the Genset controller into closed state with a subsequent "step- function" sharp increase of the charge current. The Genset controller starts a charging sequence of the battery bank. In this charging sequence, the charge current is not controlled.

- Step_D: The battery bank voltage increases slowly until reaching the nominal Genset DC output voltage where the engine rpm is maintained at a corresponding constant value.

- Step_E: The Genset controller keeps the Genset output voltage at constant value at the nominal Genset DC output voltage. Close to full charging of the batteries indicated by the constant battery voltage, the charge current decreases slowly.

- Step_J: When the charge current falls below the stop current percent, the Genset controller opens the load contactor and activates the idle speed output (if enabled). 31 - Step_K: Engine cooldown period.

- Step_L: The engine comes to rest. The load consumes power from the battery bank. The battery bank voltage decreases slowly with discharge level. The Genset controller waits until the battery bank voltage falls below the start new charge voltage, to restart new charging cycle and a new charging sequence is repeated.

In another embodiment, the charging method of the hybrid power supply generator is provided, wherein steps B and C are replaced by the following steps: - Step B’: The engine is restarted with the Genset controller; the engine reaches a predetermined rpm and is kept at constant speed; - Step C’: the load contactor is toggled by the Genset controller into closed state with a subsequent increase of the charge current; The Genset controller starts a charging sequence of the battery bank; - Step D’: The Genset controller regulates the voltage on the generator/Genset rotor for inducing a gradually increased current value at the stator and the generator/Genset output till reaching a constant required DC current value; the Genset controller may take current from the rechargeable batteries or the stator for monitoring and regulating the voltage on the rotor in the generator and the output current of the generator; - Step E’: after reaching the required current charging value, the Genset controller ensures constant current at the output of the generator during recharging of the battery bank.

Brief Description of the Drawings Fig. 1 Illustrates a schematic flow chart box of a hybrid high power supply current/voltage system and apparatus in one preferred embodiment of the present invention.

Fig. 2 illustrates a schematic diagram of the hybrid high power current/voltage generator system and apparatus of the present invention in one preferred embodiment of the present invention.

Figs. 3A-F illustrate a schematic diagram and pictures of several main parts of the hybrid high power current/voltage generator system and apparatus, shown at Fig. 2. 32 Figs. 4A-C show real image of the Genset controller apparatus including a detailed description of its control panel including its indicators diagram and its related electric circuit.

Figs. 5A-C illustrate a schematic diagram of a hybrid high power current/voltage generator system/Genset in one preferred embodiment of the present invention.

Fig. 6 shows a graph of measured charging parameters of the hybrid high power generator/Genst during a typical charging sequence.

Figs. 7A-B illustrate the operation cycles of the hybrid high power generator system for two typical operational charging cycles, marked as "optimal" (Fig. 7A) and "uncontrolled" (Fig. 7B) charging cycles in two particular embodiments of the present invention.

Detailed Description of the Drawings Fig. 1 illustrates schematics in the form of a box flow chart of a hybrid high power current/voltage generator system (100) in one preferred embodiment of the present invention. The system (100) comprises a diesel driving engine/motor (2), a DC power current supply generator/Genset (3) (labelled Genset) comprising an AC current supply generator (3a), an AC to DC modification unit and a regulation unit (3b), a Genset controller unit (1) with monitoring and regulator units and a bank of batteries which comprises a plurality of Lithium-Iron (Li-Fe) or other type of rechargeable batteries (7a-7n). The diesel driving engine/motor is coupled to the generator/Genset (3) through mechanical means (4), driving it in a relatively short period of time to a certain target value of high DC supply current of about 500A-1000A.

The generator/Genset (3), driven by the diesel engine/motor (2), is monitored and controlled by the Genset monitoring and regulating controller (1) via the electrical and communication interface means (8a). This configuration enables to achieve a short- time stabilization locking response of the generator's current, which comprises a preliminary ramp current accompanied by further stabilization on a current magnitude value. Next, the DC current supply generator/Genset promptly charges the batteries (7a-7n) via the electrical interface (6). The Genset controller (1) monitors the generator/Genset output current and voltage via the electrical and communication 33 interface means (8a), the voltage of the rechargeable batteries (7a-7n) and the diesel driving engine (2) via the communication interface means (8b, 8c), respectively. The Genset controller (1) monitors and controls the generator/Genset electrical power (measured in Killo-Watts, KW), the motor RPM (Rounds/cycles Per Minute), the diesel engine/motor cooling water temperature and the oil pressure magnitude and temperature.

The charging process is enhanced due to the interface of the Genset controller (1) with the engine/motor (2), the DC generator/Genset (3) and the rechargeable bank of batteries (7a-7n). In this configuration, the Genset controller (1) monitors the instantaneous charging voltage of the rechargeable batteries (7a-7n), the output current generator/Genset and the engine electrical performance, enabling it to optimise and manage efficiently the charging process of the batteries in a short period of time. At a charging cycle, the Genset controller (1) can couple or decouple the engine (2), the DC generator/Genset (3) and the plurality of batteries (7a-7n) units to achieve an optimal charging cycle. It forces constant output current from the generator by replacing the voltage regulator and controlling an inductor coil or other voltage application means on the rotor to induce the required magnetic flux on the stator. It also stops charging after completion of a charging cycle. This results in a highly efficient, high power hybrid generator/Genset. The diesel driving engine/motor (2) consumes only a low amount of fuel in each charging cycle of several hours, which is sufficient for long operational time, for example a full day or more.

Fig 2 illustrates a schematic diagram of the hybrid high power current/voltage generator system (100) in one particular embodiment of the present invention. The diesel driving engine/motor (2) is not shown. In this setup, the DC generator/Genset (3) is driven by diesel driving engine/motor, and is further connected via an electrical line to the switch 12 power bar control unit (1b, see Fig. 3A).

The 24 DC load (1a) monitors the instantaneous voltage and current on the load contactor (not shown in Fig. 2) and controls its state. When recharging the 24 DC load closes the load contactor that connects to the batteries. When the load contactor is disconnected, it means that the batteries are not charged and the 24 DC load channels the current to the ground. 34 In one embodiment, the Genset controller (1) is connected to the 12 power bar unit (1b) via a wire data communication control means (1'). In a further embodiment, the Genset controller (1) is further connected to the 12 power bar unit (1b) via a plurality of electrical actuating and sensing control means. The Genset controller (1) and the 12 power bar particular design are disclosed in Figs. 4A-C and Figs. 3A-B including the particular electrical circuit design and its input and output voltage sensing actuation and data terminals. In a further embodiment, the Genset controller (1) is connected to the 12 power bar control unit (1b) via wireless data WiFi, Bluetooth or other wireless control means (1'). The Genset controller (1) utilizes wire or wireless communication protocols including network software and hardware means and other corresponding communication and control protocols. Through the 12 power bar unit (1b), which is connected to the system parts, the Genset controller (1) is connected to the main components of the system (100) via a plurality of electrical voltage/current lines and via a plurality of input and output data lines, as shown in Fig.2. The Genset controller (1) utilizes the power-bar unit (1b), for optimal distribution of the charging current via the electrical lines (6a-6f) to a corresponding plurality of Lithium-Iron (Li-Fe) rechargeable batteries (7a-7f).

The Genset controller (1) output and input terminals monitor sense, manage and control the hybrid high power system (100) components of the engine (2), generator/Genset (3), rechargeable batteries (7a-7n), optimizing the charging process of the plurality of rechargeable batteries (7a-7n).

In this configuration, the electrical recharging lines (6a-6f) comprise, a plurality of latching relay 24/500A units (6a'-6f') which monitor the recharging process which can start and stop the recharging current to the related batteries (6a-6f). The current voltage and data input and output terminals are shown in Figs. 3A-C.

In one embodiment, each of the electrical recharging lines (6a-6f), which are connected through the 12 power bar unit (1b) between the Genset controller (1) and the plurality of relay units (6a'-6f'), further comprise additional data control lines for monitoring the remote control of the plurality of relay units (6a'-6f'). The plurality of relay units (6a'-6f') are remotely monitored and controlled by the Genset controller (1). In this particular design, the Genset controller (1) is connected to the 12 power bar unit (1b) via a wire or wireless WiFi, Blewthooth or other wireless control means (1'), comprising wireless network hardware, software and communication protocols.

Through the 12 power bar unit (1b), the Genset controller (1) controls all the parts of the hybrid high power current/voltage generator system (100).

In a further embodiment of the present invention, the plurality of latching relay 24V/500A units (6a'-6f') monitors the instantaneous voltages, instantaneous recharging current and total charging level of the rechargeable batteries (7a-7f). Based on predetermined set of rules, the smart Genset controller (1) can decide which of the plurality of relay units (6a'-6f') to toggle to an "ON" open state enabling recharging of the corresponding rechargeable batteries (7a-7f) and which of the relay units (6a'- 6f') will be toggled to an "OFF" state which electrically disconnects it from some of the rechargeable batteries (7a-7f), disabling a recharging process.

The first step the system (100), is an acquisition process of the charging current, stabilizing it on predetermined charging current value, wherein the typical charging values are between 500-1000A.The plurality of batteries are connected to a plurality of 24/240 V electrical adaptors (10a-10c) through a master bus network (9), type Combi pro 24/3500 100 (230V). The electrical adaptors (10a-10c) are connected to AC-IN and AC load lines (12a, 12b) respectively, feeding a plurality of electrically connected loads. The electrical adaptors are connected through the MasterBus network (9) to a Master Bus USB interface unit (9b), a multipurpose contact output (9c) and an easy view screen (9a). The Master Bus USB interface unit (9b) and easy view screen (9a) enable to both monitor and supervise the performance and status of the system (100). This includes monitoring and supervising of the charging condition of the rechargeable batteries (7a-7f) and the available power of the system (100) and the required electrical power by the plurality of connected loads (12b). The Master Bus USB interface unit (9b) enables also to externally control the system (100), further identifying problems, malfunctions and errors and executing troubleshooting protocols. The Multipurpose contact output unit enables to supervise the condition of the system (100) through other interface view means. 36 In a further embodiment, the Genset controller (1) can be directly connected to some or all of the system parts such as the shown DC generator/Genset (3), diesel driving engine/motor (2), rechargeable batteries (7a-7f), latching relay units (6a'-6f'), plurality of 24/240 V electrical adaptors (10a-10c) and MasterBus network (9).

Figs. 3A-F illustrate a schematic diagram of the several main parts of the system (100) shown in Fig. 2. Figs. 3A-B illustrate a side perspective and a top view of the 12 power- bar apparatus (1b), shown with a related detailed description in Fig. 2. The 12 power- bar switch apparatus (1b) comprises a base part (101), a 12 positions power boost bar, wherein each boost bar is composed of serrated flange nuts (103) and a /16 – 18x1.25 self clinching SS stud parts; a power bar support part (104); a plurality of screws types 0-24x3/8 (106), 8-32x5/16 screw ETLW (107) and a cover part (105) for the 12 power- bar. Figs. 3C-E show real images of the easy view screen (9a), the 24/240 V electrical adaptors (10i), type Combi pro 24/3500 100 (230V) and the multipurpose contact output (9c).

Fig. 3F shows real image of the electrical interconnects platform (13), which can be used in the system (100). Such electrical interconnects apparatus can be integrated at the 12 power-bar unit (1b). In this case, the electrical interconnects comprise high- temperature fibre reinforced base materials (13a) for strength and chemical resistance, a plurality of stainless steel studs, washers and nuts (13b), a Tin plated copper conductor (13c), radius bar ends and generous stud lengths improving cable routing options for large cables (13d), a plurality of covers feature snap-outside skirts for additional cable entry, as required (13e), an innovative clear cover that insulates/protects on three sides, which include recesses for convenient labeling (13f).

The electrical interconnect (13) features a common interconnection height, which makes it easy to ‘cluster’ several products. Modular assemblies offer flexibility in the design and layout. The selected electrical interconnects also feature reduced individual footprints and save additional space for the most compact installations, a robust construction. 37 Figs. 4A-C show real images of the Genset controller (1) including a detailed description of its control panel, indicators diagram and related circuit.

Fig. 4A shows the control panel (200) diagram of the Genset controller apparatus (1) including a detailed description of its control buttons and their related functionalities.

The control panel (200) comprises the following buttons: a run mode or stop button (201) ; a Test mode button (202); an Auto mode button (203); a stop mode button (204); an Alarm mute button (205); a next and previous display button (206A, 206B); a Lamp test (by a held pressed) button (207).

Figs. 4A-B show the corresponding indicators diagram of the control panel (200) diagram of the Genset controller (1). The control panel (200) comprises the following indicators description: a service request indicator (208); a fault condition indicator (209); an LCD Graphic LCD screen indicator (210); a Mimic Diagram and system status (211;) a shut down alarm indicator (212); a warning indicator (213); a Service request indicator (214); a test mode indicator (215); a run mode indicator (216); an Auto mode indicator (217); a STOP mode indicator (218); a Genset indicator (219); a load contactor indicator (220).

As specified for Fig. 2, the Genset control panel, including its related monitoring means, enables the user to actively run, control and monitor the Hybrid AC/DC electrical power-supply system via a wire or wireless communications means. This enables to monitor any response of its various parts, monitor the system status and performances during its various running operational modes such as manual, Auto run, Test and other running operational modes.

In a further embodiment of the present invention, the Genset controller (1) is an advanced DC controller for both variable and fixed speed systems. It is presented in three different versions, as ANALOG DRIVE, POWER DRIVE and CANBUS DRIVE. The controller has a precision PID loop providing exact matching of the optimal charging characteristics, as well as overvoltage, overcurrent, overspeed, overheat protections. The POWER DRIVE version provides a 7 Amp-DC output, interfacing directly to the engine actuator or alternator excitation winding without the 38 need for a governor controller or AVR. The CANBUS DRIVE version connects to ECU driven electronic engines providing engine control, protection and instrumentation without extra senders. ECU alarms are displayed in text. All versions offer a 0-10 Volts analog output for speed or voltage control. The fixed speed operation stops the Genset (3) precisely when batteries (7a-7n) are fully charged, providing fuel economy and maintenance cost reductions. The unit has precision, fully isolated measuring inputs for the battery bank (7a-7n) voltage and charge current. It supports both “positive to ground” and “negative to ground” installations. The current is measured through a DC current shunt placed in positive or negative output of the Genset. An example of a 60 mV DC input shunt resistor is shown in Fig. 4C marked as (338) with current positive/negative measurement inputs (301/302).The measurement is done by a connection of the current output terminals measuring of shunt resistor (338) to these terminals.

The Genset (3) starting is based on the precisely measured DC battery bank voltage.

Once started, the controller will perform an optimal battery charging cycle and will stop the Genset when batteries are fully charged. The optimal charge algorithm allows maximum battery life and minimal engine run time and fuel consumption. During a charge cycle, the Genset control unit (1) controls the engine (2) rpm (or excitation) in order to apply the exact required DC voltage and current to batteries. The rpm control over CANBUS-J1939 is available for electronic engines. The unit offers a PT100 type, battery temperature sensor input. If used, the temperature protection will allow longer battery life in hot environment and faster charge in cold conditions.

The Genset controller (1) is designed with the following features: Compatible with 12V, 24V and 48V DC systems; a DC power drive output (7A-DC); an ECU connection through J1939 CAN option 0-10V analog control output; isolated Volt - Amp measurements; a battery temperature input for PT100 sensor; optimal charging, providing longer battery life; temperature dependent battery charging level; thermal protection, short circuit protection and a dual Genset mutual standby operation with 100 event logs with time stamp and measurements; a battery backed- up with a real time clock; a built-in daily/weekly/monthly exerciser; field adjustable parameters; an RS-232 serial port; a Free MS-Windows Remote monitoring SW GSM 39 and PSTN modem support GSM SMS message sending on fault MODBUS communications; multiple language support and customer logo display capability.

The Genest controller (1) can perform the following measurements: The rechargeable batteries (7a-7n) voltage and temperature and charging level, The generator/Genset (3) voltage, current and power of the engine rpm, the battery voltage, the coolant temperature, the Oil Pressure and temperature and the fuel level.

Fig 4C illustrates a schematics diagram of the electrical circuit (300) of the Genset controller unit (1). The electrical circuit comprises the following parts: - A current positive/negative measurement inputs (301/302) with 60 mv DC input.

Measurement is done by a connection of the current output terminals measuring of shunt resistor (338) to these terminals. The current measurement circuit is isolated from the rest of the device. Thus, the current shunt may be placed in positive or negative branch of the alternator without affecting the measurement quality.

- A negative and positive DC alternator output voltage (303/304) and a DC Load positive terminal (306). The DC alternator (336) and load outputs are connected to these terminals. The polarity must be correct and the supply of current values, which must not be larger than at a threshold value in order to avoid the unit to display faulty current measurements and corresponding damage to the unit. Two positive and negative output voltage terminals connect to loads (337a, 337b).

- Load contactor terminals (306, 308), a load contactor common terminal (307), wherein these terminals provide energy to the load contactor (306a, 306') with a related switch. An analog output (309) is with voltage of 0-10 DCV.

In this configuration, the J1939 electronic ports (310', 311') of this engine are connected to these terminals. MPU (310a) + /- voltage terminals (310/311) are AC analog input of 1.0 to 100 Volts.

Temperature measurement inputs (312/313) are connected to sensor input of the battery bank (7a-7n). The related temperature sensors are used by the Genset controller (1) to protect the battery bank from overheating during a charging cycle.

- Two plus/minus actuator outputs terminals (312/313) with maximum current of 10A.

These outputs supply energy to the electric actuator. The actuators output voltages (312/313) will be increased by the controller in order to supply more fuel to the 40 engine. A further short protection circuit is provided to this module, by a ground (316) with zero DCV with negative power supply connection. A +12/24 VDC battery positive terminal (317) of the DC Supply is connected to this terminal. The unit operates on both 12V and 24V battery systems. Positive and negative output voltage terminals are connected to load (337a, 337b).

- Further are provided, fuel level (318), oil pressure and temperature (318, 334) and coolant temperature senders (320). All senders are based on analogue sender connection with a variable resistance elements (318', 319', 334', 320') having variable input resistance of 0-5000 Ohms.

- A charge input and output terminal (321) is connected to charge alternator (321') which is connected to alternator WL/D+ terminal. This terminal supplies the excitation current and measures the voltage of the charge alternator.

- A start relay (324'), fuel relay (325'), relay-1 (323') and a relay-2 (322') output voltage and current terminals (1A/28DCV) with corresponding electrical switches (324, 235, 323, 322), respectively. The start relay (324'), fuel relay (325') voltage output terminals are assigned to programmable functions selectable from a list of optional functions of the Genset controller (1). The start relay (324') and a fuel relay (325') output voltage and current terminals control the engine cranking and fuel solenoid, respectively. Also is provided a plurality of the following digital inputs: An emergency stop (326), Spare-2 (327), program lock (328), Spare-1 (329), coolant level (330), high temperature (331), low oil pressure (332) and a rectifier fail (333).

These inputs have programmable characteristics selected via the program menu. Each input may be driven by a ‘normally closed’ or ‘normally open’ contact, switching either battery + or battery- voltage condition, with the related switches (329', 330', 331', 332', 333'). The effect of the related switches is also selectable from a list as specified in details at the controller programming module. (335) is a general common ground line.

In one preferred embodiment of the present invention, The Genset controller is labeled as OR379 which has been developed with the disclosed particular 41 preferences. The controller has been designed for sensing, monitoring, actuation and controlling the Hybrid High Power Generator of the present invention, as specified following Sections I-XXII and at the detailed description relating to Figs. 2, 4A-C.

Further detailed description is disclosed at the summary apparatus section.

Figs. 5A-D illustrate a schematic diagram of a hybrid high power current/voltage generator system (100) in one embodiment of the present invention. Fig. 5A illustrates a side perspective-view of the hybrid high power generator system (100) of the present invention. As shown in Fig. 5A, the system (100) is embedded inside an isolated closed platform, enabling it to be sally moved between different locations.

Fig. 5B illustrates a side-perspective exploded-view of the top and bottom parts (100a, 100b) of the system (100). The isolation embedding platform comprises a top cover part (100a) and a box bottom part (100b). The top part (100a) embeds the Genset controller (1) (not shown), a plurality of interfaces for monitoring and controlling means such as (100c). The top cover part (100a) comprises a plurality of doors (100d) enabling a quick and easy access to the system various controlling and monitoring and other embedded parts. Figs. 5C-D show a perspective view and an exploded view of the bottom part of the hybrid high power generator system (100). As shown in Figs. 5C-D, the bottom part (100b) accommodates the diesel engine (2) with its related fuel tank (2a) assembled on a frame (2c) and a set of a plurality of rechargeable batteries (7a-7g).

The embedded inside an isolated closed platform has a full electrical and acoustical isolation during its operational stage. The generator can be configured to supply a single or three phase current-voltage source as required by the application. Finally, the system (100) comprises insulation and protection covers that impart it maximum versatility and allow it to operate in various outdoor locations under different environment and weather, temperature and humidity conditions.

Fig. 6 shows a graph of measured charging parameters of the system (100) during a typical charging cycle with a related sequence. The graph shows the linear growth of the normalized charging level as a result of the certain charging current profile, I_ch, normalized to its maximum charging value (I_ch/I_max), at constant value of applied 42 charging voltage VDC. This typical charging response is achieved during a single charging cycle and a related sequence, and is achieved by simultaneous monitoring and regulation of the Genset engine (3) RPM and voltage .

Figs. 7A-B illustrate the operation cycles of the system (100) for two typical operational charging cycles, marked as "optimal" (Fig. 7A) and "uncontrolled" (Fig. 7B) charging cycles in two particular embodiments of the present invention. The system flow chart, configuration and schematics are illustrated in Figs. 1-2 and 5, with the related parts in Figs. 3-4. The Genset controller (1) monitors the conditions and regulates the system various parts executing the charging cycles, shown in Figs. 7A-B, of the plurality of electrically charged batteries (7a-7n).

Fig. 7A illustrates a time line graph of the battery voltage (a), the Genset voltage (b), the Engine rpm (round per minute) (c) and the charge current (d) during an optimal current charging cycle.

Step A: The Genset (3) is at rest. The electrically attached load consumes power from the battery bank (7a-7n). The battery bank voltage (a) slowly decreases with discharge level. When the battery bank voltage (a) falls below a certain defined start to charge voltage, after the charge voltage threshold timer step is done, the Genset controller (1) detects that the battery bank (7a-7n) is at a discharged state and decides to run the Genset (3).

Step B: The engine (2) is started, the Genset output voltage (b) increases with the Engine rpm (a) increase. The Genset controller (1) adjusts the Engine rpm (c) in order to match exactly the battery bank voltage (7a-7n) to the output voltage of the Genset/generator. When voltage matching is reached, the load contactor (1a') is closed. Thus load (1a) switching is performed with zero current. This provides longer contactor life.

Step C: The Genset controller (1) increases the Engine rpm (c) until reaching the maximum value for the charging current (d), which sharply increases its preset value. 43 Step D: The Engine rpm (c) is controlled and increased in order to keep the Charge current (d) at a constant value/state, at its maximum preset value. The battery bank voltage (a) increases slowly until reaching the nominal charge voltage.

Step E: The engine rpm (c) is controlled in order to keep the battery bank voltage (a) at the nominal charging voltage, wherein charge current (d) decreases slowly during this step.

Step F: When the charge current (d) falls below the boost-start current, the Genset controller starts the optional boost charge cycle. At the start of the optional boost charge cycle, the Genset controller re-boosts the charging current (d) by an increase of the Engine rpm (d) and a corresponding sharp increase of the charge current (d).

Step G: The maximum charging current (d) is maintained at its maximum constant value until the battery voltage (a) reaches the nominal boost voltage. The Genset controller (1) increases the Engine rpm (c) slowly until reaching the maximum charging current. The battery bank voltage (a) increases slightly with charge percentage.

Step H: The rpm is controlled in order to keep the battery bank voltage at nominal boost voltage. The charge current decreases slowly.

Step J: When the charge current falls below the stop current percent, the Genset controller decreases the Engine rpm (c) until the charge current (d) reaches a zero value, then opens the load contactor and decreases the Engine rpm (c) until idle speed.

Step K: The idle speed is kept constant until the end of cooldown period.

Step L: The engine comes to rest. The load consumes power from the battery bank.

The battery bank voltage decreases slowly with discharge level. The Genset controller (1) waits until the battery bank voltage falls below the start new charge voltage, to restart new charging cycle and a new charging sequence is repeated. 44 Fig. 7B illustrates a timeline graph of the battery voltage (a), the Genset voltage (b), the Engine rpm (rounds per minute) (c) and the charge current (d) during an uncontrolled current charging cycle.

Step A: The Genset (3) is at rest. The load consumes power from the battery bank (7a-7n). The battery bank voltage (a) decreases slowly with discharge level. When the battery bank voltage falls below the start to charge voltage, after the charge voltage threshold timer, the Genset controller (1) detects that the battery bank is discharged and decides to run the Genset (3).

Step B: The engine (2) is restarted with the Genset controller (1). The Genset output voltage (a) drives to increase Engine rpm (c), driving a subsequent increase of the Genset voltage (b).

Step C: After completion of the Genset Contactor Timer, the load contactor (1a') is toggled by the Genset controller (1) into a closed state with a subsequent "step- function" sharp increase of the charge current (d). The Genset controller starts a charging sequence of the battery bank (7a-7n). In this charging sequence, the charge current (d) is not controlled.

Step D: The battery bank voltage (a) increases slowly until reaching the nominal Genset DC output voltage, where the engine rpm (c) is maintained at a corresponding constant value.

Step E: The Genset controller (1) keeps the Genset output voltage (b) at constant value at the nominal Genset DC output voltage (b). Close to full charging of the batteries indicated by the constant battery voltage (a), the charge current (d) decreases slowly.

Step J: When the charge current (d) falls below the stop current percent, the Genset controller (1) opens the load contactor (1a) and activates the idle speed output (if enabled).

Step K: Engine cooldown period. 45 Step L: The engine comes to rest. The load consumes power from the battery bank.

The battery bank voltage decreases slowly with discharge level. The Genset controller (1) waits until the battery bank voltage falls below the start new charge voltage, to restart new charging cycle and a new charging sequence is repeated.

In another embodiment, the charging method of the battery bank by the generator is provided, wherein the charging process comprises the following sequence of steps in an uncontrolled charging sequence: - Step A: The Genset is at rest. The load consumes power from the battery bank, the battery bank voltage decreases slowly with discharge level, when the battery bank voltage falls below the start to charge voltage, after the charge voltage threshold timer, the Genset controller detects that the battery bank is discharged and decides to run the Genset.

- Step B: The engine is restarted with the Genset controller. The engine reaches a predetermined rpm and is kept at constant speed. The Genset controller regulates the voltage on the generator/Genset rotor for inducing constant current at the stator and the generator/Genset output. The Genset controller may take current from the rechargeable batteries or the stator for monitoring and regulating the voltage on the rotor in the generator and the output current of the generator. In either way, the Genset controller ensures constant current at the output of the generator during recharging of the battery bank.

- Step C: After completion of the Genset Contactor Timer, the load contactor is toggled by the Genset controller into closed state with a subsequent "step- function" sharp increase of the charge current. The Genset controller starts a charging sequence of the battery bank.

- Step D: The battery bank voltage increases slowly until reaching the nominal Genset DC output voltage where the engine rpm is maintained constant.

- Step E: The Genset controller keeps the Genset output current at constant value at the nominal Genset DC output current. During charging the battery bank, the Genset controller monitors the generator/Genset, engine and battery bank and 46 adapts applied voltage on the generator rotor in accordance with the charging state to maintain current output.

- Step J: When the battery bank is completely recharged, the Genset controller opens the load contactor, which sharply stops recharging of the batteries and activates the idle speed output.

- Step K: Engine cooldown period.

- Step L: The engine comes to rest. The load consumes power from the battery bank. The battery bank voltage decreases slowly with discharge level. The Genset controller waits until the battery bank voltage falls below the start new charge voltage, to restart new charging cycle and a new charging sequence is repeated.

In yet further embodiment, the charging method of the battery bank by the generator is provided, wherein the charging process comprises the following sequence of steps in an uncontrolled charging sequence: - Step A: The Genset is at rest. The load consumes power from the battery bank, the battery bank voltage decreases slowly with discharge level, when the battery bank voltage falls below the start to charge voltage, after the charge voltage threshold timer, the Genset controller detects that the battery bank is discharged and decides to run the Genset.

- Step B: The engine is restarted with the Genset controller. The engine reaches a predetermined rpm and is kept at constant speed. The Genset controller regulates the voltage on the generator/Genset rotor for inducing a gradually increasing current at the stator and the generator/Genset output. In yet a further embodiment the comprising an apparatus for exitacoil Genset controller utilize a partial part of the current on the stator unit may take current from the rechargeable batteries or the stator for monitoring and regulating the voltage on the rotor in the generator and the output current of the generator. In either way, the Genset controller ensures constant current at the output of the generator during recharging of the battery bank. 47 - Step C: After completion of the Genset Contactor Timer, the load contactor is toggled by the Genset controller into closed state with a subsequent "step- function" sharp increase of the charge current. The Genset controller starts a charging sequence of the battery bank.

- Step D: The battery bank voltage increases slowly until reaching the nominal Genset DC output voltage where the engine rpm is maintained constant.

- Step E: The Genset controller keeps the Genset output current at constant value at the nominal Genset DC output current. During charging the battery bank, the Genset controller monitors the generator/Genset, engine and battery bank and adapts applied voltage on the generator rotor in accordance with the charging state to maintain current output.

- Step J: When the battery bank is completely recharged, the Genset controller opens the load contactor, which sharply stops recharging of the batteries and activates the idle speed output.

- Step K: Engine cooldown period.

- Step L: The engine comes to rest. The load consumes power from the battery bank. The battery bank voltage decreases slowly with discharge level. The Genset controller waits until the battery bank voltage falls below the start new charge voltage, to restart new charging cycle and a new charging sequence is repeated.

Claims (39)

266432/2 48 Claims

1. A hybrid, high power generator system comprising: - a driving engine with electro-mechanical coupling means to a DC high power current supply generator (labeled as Genset) through mechanical and electrical 5 input interface means, with at least one electrical input interface for external control and regulation of an engine RPM with external control means; - a battery bank comprising a plurality of rechargeable batteries with electrical charging means with externally controlled interface with electrical monitoring interface means; 10 - said generator/Genset comprising: an alternator module; an AC to DC module and an electro-mechanical coupling interface means with said driving engine and an electrical charging interface means with at least one electrical control interface means with said plurality of rechargeable batteries, at least one electrical monitoring input interface means for output voltage and charging 15 current of said generator/Genset and at least one electrical input interface for regulation of output voltage and charging current values of said generator; - a load contactor configured to connect said battery bank to said Genset in recharging mode and disconnect said battery bank off of said Genset upon completion of said recharging; 20 - a plurality of electrical voltage and current interconnect lines and a plurality of data interconnect lines; - a Genset controller with interface monitoring and sensing means with said generator and direct contact with and control of magnetic field generating means in said generator/Genset, with said driving engine and with said 25 plurality of rechargeable batteries, said Genset controller comprising an electrical control interface means for controlling output current and voltage of said generator/Genset, of said plurality of rechargeable batteries and of said driving engine RPM, said Genset controller comprising at least one switching and actuation means for controlling connection between said generator/Genset 30 and said driving engine and between said generator/Genset and said plurality of rechargeable batteries; 266432/2 49 wherein said Genset controller is connected via said plurality of said electrical and data interconnect lines to said interface means of said generator/Genset, to said interface means of said driving engine and to said interface means of said plurality of rechargeable batteries, 5 wherein said Genset controller replaces a voltage regulator in said generator/Genset to control an inductor coil or other voltage application means on a rotor in said generator/Genset to induce magnetic flux by said rotor on a stator in said generator/Genset and sustain output current at selected constant value, said Genset controller is configured to monitor supply voltage of said plurality of 10 rechargeable batteries and launch a charging cycle of said plurality of rechargeable batteries upon drop below pre-defined threshold values, wherein during a charging cycle of said plurality of rechargeable batteries or during idle phase, said Genset controller utilizes electrical actuating and switching means which are configured to disconnect and regulate the output voltage and charging 15 current of said generator/Genset with said plurality of rechargeable batteries, while sensing and monitoring the engine RPM and generator/Genset voltage, wherein said Genset utilizes said stator and rectifying means to drive said rotor at selected DC current and the stator unit to a certain required AC power, wherein per predefined conditions of said engine RPM and generator/Genset voltages, said 20 Genset controller toggles said at least one switching and actuation means for optimal charging of said rechargeable batteries, wherein said Genset controller is configured to minimize electrical power loss of charging process, engine fuel and charging time of said generator/Genset and ensure charging conditions at acceptable working parameter values. 25

2. The system according to claim 1, wherein transmission means is configured on said stator and comprising excitation solenoid and the rotor unit comprises a receiving solenoid, wherein power between the rotor and stator is transmitted through induction. 30

3. The system according to claim 1, wherein transmission means is configured on said stator and comprising a pair of slip rings and brushes. 266432/2 50

4. The system according to claim 1, wherein said driving engine further comprising at least one monitoring means for engine conditions selected from engine temperature, fuel and oil levels, oil pressure and temperature, coolant liquid level and temperature, engine battery and coils functional condition. 5

5. The system according to claim 1, wherein said of least one switching and actuation means of said Genset controller comprises a load contactor and a related switch which are toggled between short and open states for enabling and disabling a charging of said plurality of rechargeable batteries and enabling charging by said 10 generator/Genset.

6. The system according to claim 1, wherein said load contactor voltage and common terminals are connected to an electrical switch which is electrically controlled by said Genset controller and which can be toggled between "open" and 15 "short" states, wherein said load contactor terminals and related switch are interconnected between said generator/Genset and said plurality of rechargeable batteries and can electrically connect or disconnect between said generator/Genset and said plurality of rechargeable batteries. 20

7. The system according to claim 1, wherein said alternator voltage matches voltage of said battery bank.

8. The system according to claim 1, wherein said generator/Genset further comprises an AC current supply generator/Genset and an AC to DC modification and 25 regulation unit.

9. The system according to claim 1, wherein said plurality of rechargeable batteries are Lithium-Iron (Li-Fe) rechargeable type batteries. 30

10. The system according to claim 1, wherein said engine/motor is a DC diesel fuel engine/motor. 266432/2 51

11. The system according to claim 1, wherein said Genset controller monitors said generator/Genset input/output voltages, input/output voltages of the bank of the plurality of rechargeable batteries, Generator/Genset electrical power, the driving engine RPM, cooling water temperature and oil pressure magnitude. 5

12. The system according to claim 1, further comprising a 12 power bar connection unit, which is connected via an electrical input and output lines on one side to other system components and on the other side to data and electrical input/output interface of the Genst controller, wherein the Genset controller utilizes said 12 10 power-bar unit for optimal distribution of the charging current via said electrical interconnect lines to a corresponding plurality of rechargeable batteries.

13. The system according to claim 12, wherein said Genset controller is connected to said 12 power bar and switch control units via a wire or wireless WiFi, Bluetooth 15 or other wireless control means comprising wireless network hardware, software and communication protocols, wherein said Genst controller controls all of the generator/Genset system through said 12 power bar unit.

14. The system according to claim 12, wherein the generator/Genset controller is 20 connected to the 12 power bar control unit via wireless data, WiFi, Bluetooth or other wireless control means, wherein said Genset controller utilizes wire or wireless communication protocols including network software and hardware means and corresponding communication and communication control protocols. 25

15. The system according to claim 12, wherein each of electrical charging lines are connected on one side to said 12 power bar and on other side to said plurality of rechargeable batteries through a plurality of latching relay units, which are controlled by said Genset controller, wherein wireless control means further comprising additional data control lines for monitoring and remote controlling the 30 plurality said relay units. 266432/2 52

16. The system according to claim 1, wherein each of electrical charging lines are connected to the generator/Genset on one side and to the rechargeable bank of batteries on their other side, and connected to an at last one latching relay 24/500A units wherein said latching relay 24/500A further comprising monitoring means of 5 charging process parameters of said plurality of rechargeable batteries, said parameters comprising charging current, voltage and charging level of said plurality of batteries, wherein said plurality of latching relay 24/500A units can be toggled between “open” and “short” states and start and stop electrical charging current of said electrically attached plurality of rechargeable batteries. 10

17. The system according to claim 1, wherein said Genset controller monitoring means are connected to electrical input/output interface monitoring means of said generator/Genset, to said driving engine and said plurality of rechargeable batteries, and execute at least part of the following measurements: Electrical 15 Genset power factor; Engine rpm, Oil pressure and temperature; Engine Coolant temperature, Fuel level, Battery voltage including Mains phase voltages L1-L2-L3 Mains frequencies, Digital input statuses, Charge input status J1939 Values, event number, event type/fault, date and time, operation mode, operation status including on-load, on-mains, cranking, alternator DC voltage value, battery bank 20 voltage values, alternator DC current, Genset controller active power (kW), battery bank temperature, oil pressure, engine temperature, fuel level, oil temperature, Canopy temperature, ambient temperature, engine rpm, battery voltage, internal temperature of charge voltage module, driver demand Engine percentage torque and actual Engine percentage torque in coupled and uncoupled 25 modes to the generator/Genset.

18. The system according to claim 1, wherein said DC current supply generator/Genset is stabilized in relatively short period of time to a selected target value of output current of between about 500 and 1000 A, wherein stabilization 30 locking response of the generator/Genset current comprises a preliminary ramp current value response accompanied by a further stabilization of current 266432/2 53 magnitude value, which is reduced linearly to zero value close to charging completion of said plurality of batteries.

19. The system according to claim 1, wherein the plurality of rechargeable batteries 5 are connected through a master bus network to a plurality of 24/240 V electrical adaptors, type Combi pro 24/3500 100 (230V), wherein said electrical adaptors are connected to AC-IN and AC load lines respectively, feeding a plurality of electrically connected loads. 10

20. The system according to claim 19, wherein said electrical adaptors are connected through a Master Bus USB interface unit to a multipurpose contact output and to an easy view screen.

21. The system according to claim 20, wherein said easy view screen enables to 15 monitor and supervise performance and status of the generator/Genset, including monitoring and supervising charging conditions of said rechargeable batteries, available power of voltage supply system of the generator/Genset and required electrical power by a plurality of connected loads, wherein said Master USB Bus interface unit further enables to externally control said system, identifying 20 problems and malfunctions and errors, executing troubleshooting protocols, wherein a multipurpose contact unit output enables to supervise condition of the system through interface view means.

22. The system according to claim 1, wherein the Genset controller module further 25 comprising a control panel which comprises the following buttons: a run mode or a stop button; an Auto mode button; a stop mode button; an Alarm mute button, and the following indicators and a plurality of led conditions indicators: a service request indicator; a fault condition indicator; an LCD Graphic LCD screen indicator; a Mimic Diagram and system status indicator; a shutdown alarm 30 indicator; a warning indicator; a Service request indicator; a test mode indicator; a run mode indicator; an Auto mode indicator; a STOP mode indicator; a Genset indicator; a load contactor indicator. 266432/2 54

23. The system according to claim 1, wherein said Genset controller is designed with the following features: Compatible with 12V, 24V and 48V DC electrical systems; DC power drive output (7A-DC); ECU connection through J1939 CAN option 0- 5 10V analog control output; isolated Volt - Amp measurements; battery temperature input for PT100 sensor; optimal charging, temperature dependent battery charging level; thermal protection, short circuit protection and a dual Genset mutual standby operation with 100 event logs with time stamp and measurements; battery back-up with a real-time clock; built in 10 daily/weekly/monthly exerciser; field adjustable parameters; RS-232 serial port; Free MS-Windows; remote monitoring SW GSM and PSTN modem support; GSM SMS message sending on fault MODBUS communications; multiple language support and customer logo display capability. 15

24. The system according to claim 1, wherein said Genset controller further comprising a current measurement input positive/negative for measurements of current measuring shunt resistor outputs, wherein current measurement circuit is isolated from the rest of the controller, wherein the current measuring shunt may be placed in positive or negative branch of the alternator without affecting the 20 measurement quality.

25. The system according to claim 1, wherein said Genset controller further comprising negative and positive DC input terminals for electrical connection with said alternator input voltages and DC Load positive and negative terminals. 25

26. The system according to claim 1, wherein electrical circuit of said Genset controller comprising temperature measurement input terminals, which are connected to temperature sensor input of the battery bank, wherein related temperature sensors are used by the Gesnset controller to protect the battery bank 30 from overheating during a charging cycle. 266432/2 55

27. The system according to claim 26, wherein said electrical circuit of said Genset controller further comprising two actuator plus/minus output terminals with current range and maximum value, wherein said actuator plus/minus output terminals can be increased by the controller module in order to supply more fuel 5 to said driving engine.

28. The system according to claim 1, wherein said Genset controller is further concocted to a short protection circuit. 10

29. The system according to claim 1, wherein a Max Charge Time parameter is provided as a measure of the plurality of batteries charging condition, wherein said Genset controller is configured to detect precisely end-of-charge condition and stop the engine before expiration of said Max Charge Time parameter which corresponds to charging level of the rechargeable batteries. 15

30. The system according to claim 1, wherein said Genset controller further comprising a +12/24 VDC battery with positive and negative voltage terminals, enabling power supply unit to operate at +12V and +24V battery systems. 20

31. The system according to claim 1, wherein said Genset controller is configured to indicate various types of "alarm" and stop or modification of system performance which indicate threshold system performances.

32. The system according to claim 1, wherein said hybrid, high power generator 25 system is embedded inside an isolated closed platform and easily moved between different locations, wherein said closed platform comprising a full electrical and acoustical isolation during operational stage, wherein said system providing maximum versatility to system performances and is able to operate in various outdoor locations under different environment, temperature, humidity and weather 30 conditions. 266432/2 56

33. The system according to claim 1, wherein said system is configured to supply a single or three phase current-voltage source as required by application.

34. The system according to claim 1, wherein said RPM is fixed at low range RPM. 5

35. The system according to claim 34, wherein said RPM is fixed at 1,500.

36. A charging method of power supply of a plurality of rechargeable batteries, said method comprising: 10 - providing a plurality of power supply rechargeable batteries, a DC voltage generator/Genset comprising an alternator and a AC to DC converter, a load contactor connected to a switch ,wherein said load contactor voltages and common terminals are connected between said DC voltage generator/Genset and said plurality of rechargeable batteries; 15 - providing monitoring means for voltage of each of the plurality of batteries, DC generator/Genset voltage, Engine rpm, charge current, a stator connected to a AC/DC electrical rectifier, wherein the following charging steps of said plurality of said rechargeable of batteries comprising the following sequence of steps in an optimal charging sequence: 20 - Step A: the Genset is at rest; the electrically attached load consumes power from the battery bank; the battery bank voltage decreases slowly with discharge level; when the battery bank voltage falls below a certain defined start to charge voltage, after the charge voltage threshold timer step is done, the Genset controller detects that the battery bank is at a 25 discharged state and decides to run the Genset, applying direct contact with and control of magnetic field generating means in said generator/Genset, said generating means comprising an inductor coil or other voltage application means on a rotor in said generator/Genset to induce magnetic flux; 30 - Step B: the engine is started, the Genset output voltage increases with the Engine rpm increase; the Genset controller adjusts the Engine rpm in order to match exactly the battery bank voltage; then voltage matching is 266432/2 57 reached, the load contactor is closed to a recharging mode; load switching is performed with zero current; - Step C: the Genset controller increases the Engine rpm until reaching maximum value for charging current which sharply increases its preset 5 value; - Step D: the Engine rpm is controlled and increased in order to keep the Charge current at a constant value/state, at its maximum preset value; the battery bank voltage increases slowly until reaching the nominal charge voltage; 10 - Step E: the engine rpm is controlled in order to keep the battery bank voltage at the nominal charging voltage, wherein charge current decreases slowly during this step; - Step F: when the charge current falls below the boost-start current, the Genset controller starts the optional boost charge cycle; at the start of the 15 optional boost charge cycle, the Genset controller re-boosts the charging current by an increase of the Engine rpm and a corresponding sharp increase of the charge current; - Step G: the maximum charging current is maintained at its maximum constant value until the battery voltage reaches the nominal boost voltage; 20 the Genset controller increases the Engine rpm slowly until reaching the maximum charging current; the battery bank voltage increases slightly with charge percentage; - Step H: the rpm is controlled in order to keep the battery bank voltage at nominal boost voltage; the charge current decreases slowly; 25 - Step J: when the charge current falls below the stop current percent, the Genset controller decreases the Engine rpm until the charge current reaches a zero value, then opens the load contactor and decreases the Engine rpm until idle speed; - Step_K: the idle speed is kept constant until the end of cooldown period; 30 - Step L: the engine comes to rest; the load consumes power from the battery bank; the battery bank voltage decreases slowly with discharge level; the Genset controller waits until the battery bank voltage falls below 266432/2 58 the start new charge voltage, to restart new charging cycle and a new charging sequence is repeated.

37. A charging method of power supply of a plurality of rechargeable batteries, said 5 charging process comprises providing means as claimed in claim 36 and a sequence of steps is in an uncontrolled charging sequence and comprising: - Step A: the Genset is at rest; the load consumes power from the battery bank; the battery bank voltage decreases slowly with discharge level; when the battery bank voltage falls below the start to charge voltage, after the charge 10 voltage threshold timer, the Genset controller detects that the battery bank is discharged and decides to run the Genset; - Step B: the engine is restarted with the Genset controller; the Genset output voltage drives to increases Engine rpm, driving a subsequent increase of the Genset voltage; 15 - Step C: after completion of the Genset Contactor Timer, the load contactor is toggled by the Genset controller into a closed state with a subsequent "step- function" sharp increase of the charge current; the Genset controller starts a charging sequence of the battery bank; in this charging sequence, the charge current is not controlled; 20 - Step D: the battery bank voltage increases slowly until reaching the nominal Genset DC output voltage, where the engine rpm is maintained at a corresponding constant value; - Step E: the Genset controller keeps the Genset output voltage at constant value at the nominal Genset DC output voltage; close to full charging of the 25 batteries indicated by the constant battery voltage, the charge current decreases slowly; - Step J: when the charge current falls below the stop current percent, the Genset controller opens the load contactor and activates the idle speed output; - Step K: engine cooldown period; 30 - Step L: the engine comes to rest; the load consumes power from the battery bank; the battery bank voltage decreases slowly with discharge level; the Genset controller waits until the battery bank voltage falls below the start new 266432/2 59 charge voltage, to restart new charging cycle and a new charging sequence is repeated.

38. A charging method of power supply of a plurality of rechargeable batteries, said 5 charging process comprises providing means as claimed in claim 36 and a sequence of steps is in an uncontrolled charging sequence and comprising: - Step A: the Genset is at rest; the load consumes power from the battery bank; the battery bank voltage decreases slowly with discharge level, when the battery bank voltage falls below the start to charge voltage, after the charge 10 voltage threshold timer, the Genset controller detects that the battery bank is discharged and decides to run the Genset; - Step B: the engine is restarted with the Genset controller; the engine reaches a predetermined rpm and is kept at constant speed; the Genset controller regulates the voltage on the generator/Genset rotor for inducing a gradually 15 increasing current at the stator and the generator/Genset output till reaching a constant required DC current value, the Genset controller may take current from the rechargeable batteries or the stator for monitoring and regulating the voltage on the rotor in the generator and the output current of the generator; the Genset controller ensures constant current at the output of the generator 20 during recharging of the battery bank; - Step C: after completion of the Genset Contactor Timer, the load contactor is toggled by the Genset controller into closed state with a subsequent "step- function" sharp increase of the charge current; the Genset controller starts a charging sequence of the battery bank; 25 - Step D: the battery bank voltage increases slowly until reaching the nominal Genset DC output voltage where the engine rpm is maintained constant; - Step E: the Genset controller keeps the Genset output current at constant value at the nominal Genset DC output current; during charging the battery bank, the Genset controller monitors the generator/Genset, engine and battery bank and 30 adapts applied voltage on the generator rotor in accordance with the charging state to maintain current output; 266432/2 60 - Step J: when the battery bank is completely recharged, the Genset controller opens the load contactor, which sharply stops recharging of the batteries and activates the idle speed output; - Step K: engine cooldown period; 5 - Step L: the engine comes to rest; the load consumes power from the battery bank. The battery bank voltage decreases slowly with discharge level; the Genset controller waits until the battery bank voltage falls below the start new charge voltage, to restart new charging cycle and a new charging sequence is repeated. 10

39. A charging method of power supply of a plurality of rechargeable batteries of claim 36, wherein steps B and C are replaced by the following steps: - Step B’: The engine is restarted with the Genset controller; the engine reaches a predetermined rpm and is kept at constant speed; 15 - Step C’: the load contactor is toggled by the Genset controller into closed state with a subsequent increase of the charge current; The Genset controller starts a charging sequence of the battery bank; - Step D’: The Genset controller regulates the voltage on the generator/Genset rotor for inducing a gradually increased current value at the stator and the 20 generator/Genset output till reaching a constant required DC current value; the Genset controller may take current from the rechargeable batteries or the stator for monitoring and regulating the voltage on the rotor in the generator and the output current of the generator; - Step E’: after reaching the required current charging value, the Genset 25 controller ensures constant current at the output of the generator during recharging of the battery bank.