US 2026/0291327 A1Published application

Mechanically coupled hybrid generator

AssigneeAlliance North America, Inc.

InventorsTravis Waineo, Michael Yin, Jeremy A. Goddard, Thomas J. Caterina, Michael F. Niemela, Kevin Speach, Gregory McFadden, Warren J. Krettek

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Abstract

A hybrid generator includes an engine, a clutch, a motor, an alternator, a motor controller, and a battery. When the engine is running, the engine rotates the motor, which rotates the alternator, which supplies power to a load. When the motor is running, the battery, via the motor controller, drives the motor to rotate the alternator. The system selectively rotates the alternator using the engine or battery power. The system will use battery power until the battery reaches a minimal state of charge. Thereafter, the engine is started and the clutch engaged to power the load and charge the battery to a maximum state of charge. At which point, the clutch is disengaged, the engine stopped, and the system reverts to battery power. Bypass modes can be used that power the load using engine power due to efficiency, system faults, extreme environmental conditions, or peak loads.

Claims21

Dependent claims

A hybrid generator configured to power an external electrical load, wherein the hybrid generator comprises:

an engine assembly, an electric motor, and an alternator;
a generator controller and a motor controller;
a battery;
a clutching mechanism arranged between the engine assembly and the electric motor and the alternator;
wherein the alternator is configured to output power to a connector for the external electrical load;
wherein the motor controller is a bi-directional device configured to power the electric motor from the battery or to charge the battery from the electric motor;
wherein when the clutching mechanism is engaged, the engine assembly is configured to rotate the electric motor and alternator together and to power the external electrical load via a power output from the alternator, and further configured to charge the battery through the motor controller;
wherein when the clutching mechanism is disengaged, the electric motor is configured to rotate the alternator to power the external electrical load via the power output from the alternator, wherein the electric motor is configured to rotate the alternator as controlled by the motor controller;
and
wherein the generator controller is configured to control at least one of the engine assembly, the clutching mechanism, the motor controller, and the electrical motor, wherein the generator controller is configured to selectively keep the alternator rotating selectively using at least one of the engine assembly and the electric motor, and wherein the generator controller is configured to operate in a charge mode when the engine assembly is running and a discharge mode when the engine is not running.

7 more elements

A hybrid generator comprising an engine assembly, a clutching mechanism, one or more electric motors, one or more batteries, one or more motor controllers, and one or more controllers;

wherein the one or more controllers are configured to select an extreme environmental conditions bypass mode when an ambient temperature causes temperatures of one or more of the one or more electric motors, the one or more batteries, or the one or more motor controllers to exceed a high temperature threshold or drop below a low temperature threshold, wherein the one or more controllers are configured to implement the selected extreme environmental conditions bypass operation mode by engaging the clutch mechanism and powering the load using only the engine assembly, wherein the one or more controllers are configured to select the extreme environmental conditions bypass mode either when the ambient temperature is above or below an ambient high temperature threshold or an ambient low temperature threshold, respectively, or when the temperatures of one or more of the one or more electric motors, the one or more batteries, or the one or more motor controllers exceeds or drops below their respective temperature ratings;
wherein, when operating in the extreme environmental conditions bypass mode due to the ambient temperature or the temperatures of one or more of the one or more electric motors, the one or more batteries, or the one or more motor controllers exceeding the respective high temperature thresholds, the one or more controllers are configured to revert to a non-bypassed mode when the temperatures of the one or more electric motors, the one or more motor controllers, or the one or more batteries have dropped below their respective high temperature thresholds;
and
wherein, when operating in the extreme environmental conditions bypass mode due to the ambient temperature or the temperatures of the one or more of the one or more electric motors, the one or more batteries, or the one or more motor controllers dropping below the respective low temperature thresholds, the one or more controllers are configured to revert to a non-bypassed mode when the temperatures of the one or more electric motors, the one or more motor controllers, or the one or more batteries have risen above their respective low temperature thresholds due to rising ambient temperatures and/or thermal propagation of heat generated by generator operation.

1 more element

Dependencies are inferred from the claim text.

Facts

Application: 19/458,060Filed 23 Jan 2026
Priority: 10 Mar 2025
Published: 24 Sep 2026
Term ends: Not estimatedThe source records don’t support an estimate.

Classification9 codes

H02K 7/108
Structural association with clutches, brakes, gears, pulleys or mechanical starters: with friction clutches
H02K 7/02
Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical…:…
H02K 7/116
Structural association with clutches, brakes, gears, pulleys or mechanical starters: with gears
H02K 7/1815
Rotary generators: structurally associated with reciprocating piston engines