TIER 03 · CONTROLLER ARCHITECTURE
The PowerCore-Hybrid controller: diesel dispatch logic refined across 1,200+ deployed microgrids.
Hybrid is not a genset with a battery bolted on. The PowerCore-Hybrid controller is a proprietary dispatch optimizer — patented, in production since 2018, and continuously improved against field telemetry from every unit shipped. It sequences diesel run-time against battery state-of-charge, load forecast, fuel cost, and emissions targets in 1-second intervals.
How it operates
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01
Load Forecasting
Predicts the 30-minute load curve from 14-day rolling telemetry, ramp-rate constraints, and the operator's published dispatch schedule.
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02
Battery Dispatch
Pre-charges the BESS asset during low-load windows; absorbs peak transients with the battery; runs the diesel at its most efficient BSFC point.
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03
Fuel Optimization
Selects which gensets run, in what order, and at what load percentage to minimize fuel burned per kWh delivered — averaging 38% less than diesel-only across the deployed fleet.
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04
Watch-Test Reporting
Logs every dispatch decision; pushes a daily performance report to the operator; flags deviations from contract before they trigger an alarm.
Why hybrid beats parallel diesel
Two 2 MW diesel gensets running in parallel can hold a 3 MW peak — but they burn fuel continuously, even at 30% load, and they rack up run-hours on the engines that shorten overhaul intervals. A single 2 MW diesel + 1.5 MW BESS holds the same peak, runs the engine at its sweet spot, and burns up to 38% less fuel per kWh delivered. The math is the same on a refinery island, a data hall, a copper mine, or a remote village.