Method for judging matching rationality of engine intercooling system for genset

Abstract

The present application relates to a kind of judging method of engine intercooling system matching rationality for generator set, it relates to the field of engine, it includes the following steps: in static record intake pressure P1 And atmospheric pressure P0, comparison is obtained first result;Engine is started, after engine is stabilized at low idle speed, record the intake pressure P2 At this time, and compared with intake pressure P1 Second result is obtained;After starting, engine rises to high idle speed, record the intake pressure P3 At this time, and compared with intake pressure P1 Third result is obtained;The result of above comparison is comprehensively given, whether the judgment of intercooling system is normal, abnormal, serious abnormality.This application uses the sensor of electronic control engine itself and is combined with the data of three power station engines commonly used working condition point, and after comparison, the qualitative result of whether matching is reasonable is given.

Description

Technical Field

[0001] This invention relates to the field of engines, and more particularly to a method for determining the appropriate matching of the air-to-intercooling system of an electronically controlled engine for generator sets. Background Technology

[0002] In current technology, power plant engines are becoming increasingly powerful, typically employing electronic control combined with air-to-air intercooling technology to enhance engine power. Air-to-air intercooling refers to the process where pressurized, high-pressure, high-temperature air passes through a cooler before returning to the engine's intake manifold and entering the cylinders. For more complete combustion, the intercooler is usually required to minimize intake pressure loss (pressure drop). Due to the specific nature of power plant engines, a significant portion of air-to-air intercoolers are matched by the customer. Factors such as technical capabilities, matching experience, and cost contribute to inconsistent intercooler quality, resulting in excessive intercooling resistance and causing problems such as insufficient engine intake, incomplete combustion, black smoke, insufficient power, and deviations in the performance specifications of the matched power plant unit.

[0003] For generator sets with inherent engine margins and normal customer usage, it's often impossible to determine if the intercooler pressure drop is excessive or if it's properly matched. However, when the engine's inherent margins are maximized, or when there are additional special usage requirements (such as high-altitude operation), improper intercooler matching can lead to significantly out-of-tolerance generator set performance. In such cases, checking the intercooler's matching typically involves installing pressure sensors on the intercooler's inlet and outlet pipes, connecting them to specialized testing equipment, and recording relevant data at different operating points after engine startup. Comparative analysis is then necessary to determine the appropriate match. Summary of the Invention

[0004] The purpose of this invention is to solve the above-mentioned technical problems and provide a method for judging the reasonable matching of the air-to-air intercooling system of an electronically controlled engine for generator sets. The method uses the engine's own sensors and compares the data from three commonly used operating points of engines used in power plants to give a qualitative result on whether the matching is reasonable.

[0005] To achieve the above objectives, the present invention provides a method for determining the appropriate matching of the intercooling system of a generator set engine, comprising the following steps:

[0006] Static recordings of intake pressure P1 and atmospheric pressure P0 are used to compare and obtain the first result.

[0007] Start the engine and wait for it to stabilize at a low idle speed. Record the intake pressure P2 at this time and compare it with the intake pressure P1 to obtain a second result.

[0008] After starting, the engine is raised to high idle speed, and the intake pressure P3 at this time is recorded and compared with the intake pressure P1 to obtain a third result;

[0009] Based on the results of the above comparisons, a judgment is made on whether the intercooling system is normal, abnormal, or seriously abnormal.

[0010] Preferably, the first result is used to confirm whether the pressure sensor is functioning properly.

[0011] Preferably, when obtaining the first result, if the difference between the intake pressure P1 and the atmospheric pressure P0 is within the error range V0, the two data are considered to be consistent, the sensor is working normally, and the next step can be carried out; otherwise, the difference is checked and investigated until it is normal.

[0012] Preferably, when obtaining the second result: if the intake pressure P2 is greater than the intake pressure P1, it is confirmed that the intake is normal; if the intake pressure P2 is less than the intake pressure P1 and the percentage difference exceeds the preset threshold V1, it is determined that the intercooler intake resistance is too high; if the intake pressure P2 is less than the intake pressure P1 and the percentage difference is less than the preset threshold V1, it is determined that the intercooler intake resistance is relatively high.

[0013] Preferably, when obtaining the third result: if the intake pressure P3 is less than the intake pressure P1 and the difference percentage is greater than the preset threshold V2, it is determined that the intake resistance of the intercooler is too large at this time; if it is less than the preset threshold V2, it is determined that the intake resistance is relatively large at this time.

[0014] Preferably, when comparing the results: if both the second result and the third result are deemed too large, then it is confirmed that the intercooler resistance is too large and the intercooler matching is seriously unreasonable; if either the second result or the third result is deemed large, then it is confirmed that the intercooler resistance is large and the intercooler matching is unreasonable.

[0015] Preferably, when comparing the results, if both the second result and the third result are deemed too large, or if one of them is deemed too large, an alarm is issued.

[0016] Preferably, the engine is equipped with an intake pressure sensor and an atmospheric pressure sensor. The intake pressure sensor is located on the intake manifold and after the intercooler, and the atmospheric pressure sensor is integrated into the electronic control unit.

[0017] Preferably, at high idle speed, the rated speed has no additional power output except for the necessary accessories provided with the engine.

[0018] The beneficial effects of this invention are as follows: This invention utilizes the working characteristics of the power plant's electronically controlled air-to-air engine itself, namely, it can collect the required data through its built-in sensors and collect data from several different operating points and compare and analyze it to determine whether the intercooling system is properly matched. This conclusion can be given in the early stages of matching the generator set with the intercooling system, avoiding the significant losses caused by subsequent rework due to unsatisfactory unit performance after the unit is assembled, or by failing to detect performance abnormalities when the unit appears normal in plains areas but is found to be seriously inadequate in special operating areas such as high-altitude areas, and then having to change the intercooling system. Attached Figure Description

[0019] Figure 1 A schematic diagram of a system applying the present invention;

[0020] Figure 2 This is a schematic diagram of the system flow for applying the present invention.

[0021] Reference numerals: 1. Air filter; 2. Turbocharger; 3. Intercooler; 4. Exhaust pipe; 5. Intake pipe; 51. Intake pressure sensor; 6. Electronic control unit; 61. Atmospheric pressure sensor. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] This invention discloses a method for judging the appropriate matching of the intercooler system of a generator set engine. It utilizes sensors in the engine and its operating characteristics to acquire three different sets of pressure data, compares them, and then determines whether the intercooler resistance is too high and whether the matching is appropriate. The engine discussed in this invention refers to an air-to-air intercooled electronically controlled diesel engine for power generation, hereinafter referred to as the engine.

[0024] During engine operation, the combustion process is what affects engine power output. This typically involves the amount of fuel and air. Modern engines generally have a relatively stable fuel composition, using high-pressure common rail or high-pressure unit pumps to deliver well-atomized fuel as required by the system. However, currently, most power plant engines use intercoolers that are matched by the customer. Due to low production barriers, low technical requirements, and intense market competition, customers have a wide variety of specifications to choose from. Even for the same engine, the intercoolers can vary greatly in quality. Excessive intake resistance after passing through the intercooler significantly affects the engine's airflow, ultimately impacting normal engine operation.

[0025] This invention employs the following steps:

[0026] ① Typically, the engine is equipped with intake pressure sensor 51 (after intercooler) and atmospheric pressure sensor 61 (integrated with the ECU). When the engine is not running and is at rest, the atmospheric pressure P0 and intake pressure P1 are acquired. At this time, the intake pressure P1 should be close to the atmospheric pressure value P0 read by the ECU. By comparison, if the difference between the two is considered to be within the confirmed tolerance V0 range, the data is considered consistent and normal, proceeding to the next step. Otherwise, the cause of exceeding the tolerance is investigated until it is within the tolerance V0 range.

[0027] ② Start the engine and wait until it stabilizes at a low idle speed, then record the intake pressure P2. Normally, the intake pressure P2 at this point should be greater than the previous static intake pressure P1. When the intake pressure P2 is greater than the static intake pressure P1, the intercooler 3 is considered properly matched. When the intake pressure P2 is less than the intake pressure P1, and the percentage difference exceeds the threshold V1, the intercooler 3 resistance is too high, indicating a serious mismatch in the intercooler system. When the intake pressure P2 is less than the static intake pressure P1, and the percentage difference is less than the threshold V1, the intake resistance is high, indicating an improperly matched intercooler system.

[0028] ③ When the engine accelerates from low idle speed to the high idle speed required for normal operation, there is no additional external load besides the load necessary for the engine's front and rear connections. It is assumed that the engine is in a high idle speed no-load state at this time. Record the intake pressure P3 at this time. Compare the values. If the intake pressure P3 is still less than the static intake pressure P1, and the percentage difference exceeds the threshold V2, it is determined that the intake resistance is too high, and the intercooler system is severely mismatched. If the intake pressure P3 is less than the static intake pressure P1, and the percentage difference is less than the threshold V2, it is determined that the intake resistance is relatively high, and the intercooler system is mismatched.

[0029] ④ Combining the judgments in ② and ③, a summary analysis is performed. If all are normal, the intercooler 3 resistance is normal and the matching is reasonable. If only one matching is unreasonable, the conclusion is that the intercooler 3 resistance is abnormal and the intercooler 3 matching is unreasonable. If more than one matching is unreasonable, a judgment of serious abnormality is given.

[0030] Specifically, the following steps are included:

[0031] ① At operating point 1, confirm that the intake pressure sensor 51 and atmospheric pressure sensor 61 (integrated with the ECU 6) are functioning normally. Electronically controlled engines typically come equipped with both intake pressure sensor 51 and atmospheric pressure sensor 61. With the engine off and stationary, this is identified as operating point 1. At this point, acquire the intake pressure P1 and atmospheric pressure P0. Perform an initial assessment. Typically, the intake pressure P1 should be close to the atmospheric pressure P0. By comparison, if the difference between the two is within the defined error range V0, the data is considered consistent, the sensors are functioning normally, and the next step can be proceeded. Otherwise, check for excessively large differences until the data is within acceptable limits.

[0032] ② Start the engine and wait for it to stabilize at idle speed. Mark this as operating point 2. Record the intake pressure P2 at this point. Perform a second judgment. The intake pressure P2 should be greater than the previous intake pressure P1. If it is greater, the intake is confirmed to be normal. If it is less than the previously recorded intake pressure P1, perform a judgment. If the intake pressure P2 is less than the intake pressure P1 and the percentage difference exceeds the preset threshold V1, the intercooler 3 resistance is judged to be too high. If the intake pressure P2 is less than the static intake pressure P1 and the percentage difference is less than the preset threshold V1 percentage, the intake resistance is judged to be high.

[0033] ③ When the engine accelerates from idle to its rated speed required for normal operation, there is no additional external load besides the load necessary for the engine's front and rear connections. At this point, the engine is in a high-speed no-load state, marked as operating point 3. Record the intake pressure P3 at this point and perform the third judgment. Under normal conditions, the intake pressure P3 should be greater than both intake pressure P1 and intake pressure P2. Compare the intake pressure P3 at this point. If it is still less than intake pressure P1, and the percentage difference is greater than the preset threshold V2, the intake resistance is judged to be too high. If it is less than the preset threshold V2, the intake resistance is judged to be relatively high.

[0034] ④ Based on the above three judgments, if both ② and ③ are deemed "too large," it is confirmed that the resistance of intercooler 3 is too high. Therefore, the conclusion can be drawn that the intercooler 3 is severely mismatched, and an alarm will be issued. If either ② or ③ is deemed "too large," it is confirmed that the resistance of intercooler 3 is too high. Therefore, the conclusion can be drawn that the intercooler 3 has too high resistance and is mismatched, and an alarm will be issued.

[0035] like Figure 1As shown, the engine is an electronically controlled engine, and it is an air-to-air intercooled type, used in a generator set. The engine has its own intake pressure sensor 51, which is located after the intercooler 3. It acquires the pressure after intercooling and transmits it to the electronic control unit 6. The engine also has its own atmospheric pressure sensor 61, which is usually integrated into the electronic control unit 6. When the engine is stationary, the electronic control unit 6 acquires the intake pressure P1 and atmospheric pressure P0 values ​​respectively, compares them, and if the difference between the two is within the allowable error range V0, then both the intake pressure P1 and atmospheric pressure P0 are considered to be working normally.

[0036] Entering operating point 2, start the engine. Once the engine stabilizes at low idle speed, record the intake pressure P2 and compare it with the intake pressure P1. If intake pressure P2 is greater than intake pressure P1, the pressure is considered normal. If intake pressure P2 is less than intake pressure P1, compare the two. If the difference exceeds the set threshold V1, the intake resistance is considered too high, indicating a serious mismatch. If the difference is less than the set threshold V1, the intake resistance is considered high, indicating an unreasonable match.

[0037] Entering operating point 3, increase the engine speed from low idle to high idle and stabilize the speed. Record the intake pressure P3 at this point and compare it with the intake pressure P1. When the intake pressure P3 is greater than the intake pressure P1, the pressure is considered normal. When the intake pressure P3 is less than the intake pressure P1, compare them. If the difference exceeds the set threshold V2, the intake resistance is considered too high, and the matching is seriously unreasonable. If the difference is less than the set threshold V2, the intake resistance is considered high, and the matching is unreasonable.

[0038] Based on the judgment results of working condition point 2 and working condition point 3 above, a final judgment result on whether the matching is reasonable can be given.

[0039] This invention utilizes the characteristics of an electronically controlled intercooled engine, namely, the engine itself has a built-in intake pressure sensor 51 (after intercooling) and an atmospheric pressure sensor 61 (built into the electronic control unit 6), which can conveniently obtain the intake pressure after intercooling and the atmospheric pressure, providing a basis for judgment. Furthermore, it also utilizes the operating characteristics of power plant engines, namely, three stable states during actual operation: shutdown, low idle speed, and high idle speed. During low and high idle speed operation, except for necessary loads, the engine is under minimum load. Data from these three different states is collected, compared, and judged, providing a basis for determining whether the intercooling system matching is reasonable.

[0040] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for determining the appropriate matching of the intercooling system of a generator set engine, characterized in that, Includes the following steps: Static recordings of intake pressure P1 and atmospheric pressure P0 are used to compare and obtain the first result. Start the engine and wait for it to stabilize at a low idle speed. Record the intake pressure P2 at this time and compare it with the intake pressure P1 to obtain a second result. After starting, the engine is raised to high idle speed, and the intake pressure P3 at this time is recorded and compared with the intake pressure P1 to obtain a third result; Based on the results of the above comparisons, a judgment is made on whether the intercooling system is normal, abnormal, or seriously abnormal. The first result is used to confirm whether the pressure sensor is working properly. When the first result is obtained: if the difference between the intake pressure P1 and the atmospheric pressure P0 is within the error V0 range, the two data are considered to be consistent and the sensor is working properly. The next step can be carried out. Otherwise, check and troubleshoot if the difference is too large until it is normal. When obtaining the second result: if the intake pressure P2 is greater than the intake pressure P1, it is confirmed that the intake is normal; if the intake pressure P2 is less than the intake pressure P1 and the percentage difference exceeds the preset threshold V1, it is determined that the intake resistance of the intercooler (3) is too large; if the intake pressure P2 is less than the intake pressure P1 and the percentage difference is less than the preset threshold V1, it is determined that the intake resistance of the intercooler (3) is large. When obtaining the third result: if the intake pressure P3 is less than the intake pressure P1 and the difference percentage is greater than the preset threshold V2, it is determined that the intake resistance of the intercooler (3) is too large at this time; if it is less than the preset threshold V2, it is determined that the intake resistance is large at this time. When comparing the results: if both the second result and the third result are deemed too large, it is confirmed that the intercooler (3) has excessive resistance and the intercooler (3) is seriously mismatched; if either the second result or the third result is deemed large, it is confirmed that the intercooler (3) has excessive resistance and the intercooler (3) is mismatched. At high idle speed, the rated speed provides no additional power output beyond the necessary accessories provided with the engine.

2. The method for judging the reasonable matching of the intercooling system of a generator set engine according to claim 1, characterized in that, When comparing the results, if both the second and third results are deemed too large, or if one of them is deemed too large, an alarm will be issued.

3. The method for judging the reasonable matching of the intercooling system of a generator set engine according to claim 1, characterized in that, The engine is equipped with an intake pressure sensor (51) and an atmospheric pressure sensor (61). The intake pressure sensor (51) is located on the intake manifold and after the intercooler (3). The atmospheric pressure sensor (61) is integrated into the electronic control unit (6).

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