FIELD

This technical disclosure relates to an electrical generator that can simultaneously output different types of electrical power, as well as output a thermal control fluid for use in thermal control of a component that may or may not be electrically connected to one of the electrical power outputs of the electrical generator.

BACKGROUND

The use of electrical generators to provide electrical power to components is known. One example use of an electrical generator is on a job site where line power (also known as utility power) may not be present or where the electrical generator is used in place of line power/utility power. In some instances, different components at a job site may require different types of electrical power, in which case separate electrical generators may be used to power the different components.

SUMMARY

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

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

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

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

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

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

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

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

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

