Dual-fuel controller for generator set

Abstract

The utility model relates to a dual-fuel controller for a generator set, which adopts a single controller to integrate a diesel oil injection control module and a methanol injection control module, reduces the use of wire harnesses, and reduces the hardware cost and the arrangement difficulty. By collecting multiple parameters such as the rotating speed, the water temperature and the load rate of an engine in real time, the blending combustion condition is intelligently judged, automatic switching between a pure diesel oil mode and a diesel oil and methanol blending combustion mode is achieved, the highest methanol replacement rate reaches 60%, and fuel consumption and pollutant emission are remarkably reduced. Meanwhile, a fault diagnosis function is achieved, the states of the sensor and the actuator are monitored in real time, the problem is accurately positioned through fault codes, and the safety and reliability of the system are improved. Protective structures such as a waterproof ventilation valve and a shock pad are adopted, the adaptability of the controller in a severe environment is enhanced, and the controller can be widely applied to a diesel / methanol dual-fuel generator set.

Description

TECHNICAL FIELD

[0001] The utility model relates to the control technology field of generator set, specifically, especially relates to a dual-fuel controller for generator set. BACKGROUND

[0002] In the industrial and power generation fields, diesel generator sets are widely used due to their strong reliability, but they have two major problems:

[0003] High fuel cost: when running on pure diesel, fuel cost fluctuates significantly with the price of diesel, especially when used as a common unit for long-term operation, the fuel cost per kilowatt-hour is relatively high.

[0004] Severe emission pollution: pollutants such as nitrogen oxides (NOx) and carbon soot particles (PM) produced by diesel combustion are difficult to meet the increasingly stringent environmental regulations.

[0005] To solve the above problems, dual-fuel engine technology (such as diesel-methanol blending) has gradually emerged, which replaces part of the diesel with methanol, reducing fuel costs and reducing pollutant emissions. However, the existing dual-fuel control system has the following technical bottlenecks:

[0006] High control cost: the traditional solution uses two independent controllers (diesel ECU and methanol ECU) to control two injection systems, which requires two sets of wiring harnesses and calibration tools, making calibration and development difficult, time-consuming, and increasing labor and material costs by 30-50%.

[0007] Low system reliability: the dual-controller communicates signals through CAN, which has complex wiring layout and is susceptible to electromagnetic interference. In addition, the data of the two controllers need to be updated simultaneously for later maintenance, and compatibility issues increase the failure rate.

[0008] The closest prior art at present is CN115217643A "Methanol-diesel mixed fuel engine and control method", which uses diesel ECU and methanol ECU to cooperatively control the engine to run on pure diesel during cold start and to blend fuel after warming up. However, this solution has the following defects:

[0009] Hardware redundancy: two controllers operate independently, requiring two sets of sensor and actuator interfaces, and the length of the wiring harness increases by more than 50%, which not only increases the cost but also occupies engine compartment space.

[0010] Complex calibration: diesel injection volume and methanol injection volume need to be calibrated separately, which prolongs the development cycle by 40%, and the matching accuracy of the two systems depends on repeated debugging, making it difficult to achieve optimal combustion efficiency.

[0011] Fault diagnosis lag: only single system failure can be detected, lack of real-time monitoring of the overall operation of the dual fuel system, when the sensor signal is abnormal or the actuator fails, the mode cannot be switched quickly or the protection mechanism cannot be triggered.

[0012] How to effectively solve the problems existing in the prior art is an important problem for the dual fuel controller for generator set. Content of the utility model

[0013] The utility model aims at solving the defects in the prior art and provides a dual fuel controller for generator set, which comprises:

[0014] The controller main body is composed of an upper shell, a lower shell, a PCBA circuit board, a connector, a waterproof air valve and a shock pad, and the PCBA circuit board integrates a diesel injection control module and a methanol injection control module.

[0015] The sensor acquisition module is connected to a crankshaft sensor, a phase sensor, a water temperature sensor, an intake temperature and pressure sensor, an oil temperature and pressure sensor and a rail pressure sensor through a wire harness to acquire engine operating parameters in real time.

[0016] The actuator control module is connected to a fuel metering unit, a diesel injector, a methanol pump and a methanol injector through a wire harness to output a control signal to adjust fuel injection.

[0017] The central processing unit (ECU) is electrically connected to the sensor acquisition module and the actuator control module, has a built-in calibration data storage unit, controls the engine to run in a pure diesel mode or a diesel-methanol blending mode according to real-time sensor signals and preset blending conditions, and has a built-in calibration data storage unit.

[0018] The fault diagnosis module monitors sensor signals and actuator states in real time, generates a fault code when an abnormality is detected, and sends the fault code to a unit module display screen through a CAN bus, and controls the engine to run at a lower level or to stop according to the fault level.

[0019] Preferably, the preset blending conditions include that the engine speed is greater than or equal to a speed threshold, the water temperature is greater than or equal to 65 DEG C, and the load rate is greater than or equal to a preset proportion, and when all the conditions are met, the ECU controls the methanol pump and the methanol injector to work, and enters the diesel-methanol blending mode.

[0020] Preferably, the PCBA circuit board is coated with an insulating layer, the waterproof air valve is arranged at the top of the upper shell to balance the internal and external pressures and prevent liquid water from entering, and the shock pad is arranged at the bottom of the lower shell to isolate the engine vibration.

[0021] Preferably, in the pure diesel mode, the ECU only controls the diesel injector to inject diesel; in the diesel-methanol mixed combustion mode, the ECU synchronously controls the diesel injector and the methanol injector, wherein the methanol injected by the methanol injector enters the combustion chamber after being atomized through the intake pipeline.

[0022] Preferably, the abnormal signals of the fault diagnosis module include sensor signal out-of-range, actuator failure or methanol liquid level below threshold value, when an abnormality is detected, the ECU performs the following operations according to the preset logic:

[0023] General fault: send fault code and control the engine to run in a limited torque degradation mode;

[0024] Serious fault: send fault code and control the engine to stop.

[0025] Preferably, the connector adopts a waterproof connector, which integrates the wire harness interfaces of the diesel injection system and the methanol injection system, and the number of wire harnesses is reduced by more than 50% compared with the traditional double-controller scheme.

[0026] Preferably, the ECU is built-in equivalent fuel consumption rate calculation module, which calculates the equivalent fuel consumption rate (Cesf) in real time according to the diesel mass flow, methanol mass flow and low heat value of the two, the formula is:

[0027] Cesf=(md+mm×Qm / Qd) / P×1000

[0028] Wherein, md is the diesel mass flow (kg / h), mm is the methanol mass flow (kg / h), Qm=19700kJ / kg is the low heat value of methanol; Qd=42500kJ / kg is the low heat value of diesel, P is the engine power (kW).

[0029] Preferably, the ECU is built-in methanol replacement rate calculation module, which calculates the methanol replacement rate (MSR) according to the diesel consumption mass flow in the pure diesel mode and the mixed combustion mode, the formula is:

[0030] MSR=(md1−md2) / md1;

[0031] Wherein, md1 is the diesel consumption mass flow (kg / h) in the pure diesel mode,

[0032] md2 is the diesel consumption mass flow (kg / h) in the mixed combustion mode.

[0033] Preferably, the upper shell and the lower shell are connected by buckles or bolts, and form a sealed cavity inside, the PCBA circuit board is fixed to the inner wall of the shell by heat-conducting silicone to achieve heat dissipation and shock resistance.

[0034] Preferably, the controller supports connection with external calibration equipment through CAN bus, and realizes unified calibration development of diesel injection parameters and methanol injection parameters by a single set of calibration tools.

[0035] Compared with the prior art, the utility model has the beneficial effects that:

[0036] 1. The single controller integrates diesel injection control module and methanol injection control module, replaces traditional two independent ECUs, avoids double-controller communication compatibility problems from the source, and improves system reliability.

[0037] 2. A single set of calibration tools is supported to perform unified debugging on diesel and methanol injection parameters, and compared with the traditional double-controller scheme, the labor cost and the later maintenance cost are significantly reduced.

[0038] 3. The ECU collects engine speed, water temperature, load rate and other parameters in real time, starts the methanol injection system only when the preset blending conditions are met, avoids the blindness of traditional single temperature threshold control, ensures stable operation of pure diesel during cold start, efficiently switches to the blending mode after warming up, and significantly reduces diesel consumption.

[0039] 4. The built-in equivalent fuel consumption rate and methanol replacement rate calculation module optimizes fuel ratio in real time and meets strict environmental protection requirements.

[0040] 5. The fault diagnosis module monitors sensor signals and actuator states in real time, generates fault codes when an abnormality is detected, and sends the fault codes to the display screen through the CAN bus, supports hierarchical processing of 'general fault limited torque degradation' and'serious fault immediate shutdown', improves fault positioning accuracy, and avoids chain damage caused by single system failure.

[0041] 6. The waterproof and breathable valve prevents liquid water and dust from entering, balances internal and external pressure, and assists in heat dissipation; the shock pad isolates engine vibration, the PCBA circuit board is fixed by heat-conducting silicone and coated with an insulating layer, so that the failure rate of the controller in harsh environments is reduced, and the service life is prolonged.

[0042] 7. The controller supports automatic / manual switching between pure diesel mode and diesel-methanol blending mode, and users can flexibly select according to fuel supply, load demand and environmental protection requirements, thereby improving the application scenarios of the unit.

[0043] In summary, the device solves the problems of high cost, low efficiency and poor reliability of the traditional dual-fuel control system through the innovative design of 'hardware integration + control intelligence + real-time diagnosis', reduces fuel cost and improves environmental performance, provides a standardized solution for intelligent control of generator sets, and has significant engineering application value and market competitiveness. BRIEF DESCRIPTION OF DRAWINGS

[0044] Figure 1The utility model provides a kind of overall structure schematic view of dual-fuel controller for generator set.

[0045] Figure 2 The utility model provides a kind of function block diagram of dual-fuel controller for generator set.

[0046] Figure 3 The utility model provides a kind of overall work flow chart of dual-fuel controller for generator set. DETAILED DESCRIPTION

[0047] The technical solutions in the embodiments of the utility model will be clearly and completely described below with reference to the drawings in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, not all the embodiments.

[0048] Referring to the drawings, the utility model provides a kind of dual-fuel controller for generator set, comprising:

[0049] Controller main body 1: by upper shell 11, lower shell 12, PCBA circuit board 13, connector 14, waterproof breather valve 15 and shock pad 16 are formed, the PCBA circuit board 13 integrates diesel injection control module and methanol injection control module;

[0050] Sensor acquisition module 2: through wire harness connection crankshaft sensor 21, phase sensor 22, water temperature sensor 23, intake temperature pressure sensor 24, oil temperature pressure sensor 25 and rail pressure sensor 26, real-time acquisition engine operating parameter;

[0051] Actuator control module 3: through wire harness connection fuel metering unit 27, diesel fuel injector 31, methanol pump 32 and alcohol sprayer 33, output control signal adjusts fuel injection;

[0052] Central processing unit (ECU) 4: with the sensor acquisition module, actuator control module electric connection, built-in calibration data storage unit, according to the sensor signal of real-time acquisition and preset blending condition, control engine runs in pure diesel mode or diesel methanol blending mode;

[0053] Fault diagnosis module: real-time monitoring sensor signal and actuator state, when detecting exception, generate fault code and send to unit module display screen through CAN bus, according to fault level control engine degraded operation or shutdown.

[0054] The dual-fuel controller of the generator set connects various sensors and actuators on the engine through a wire harness. After normal power-up, the dual-fuel controller can collect sensor signals in real time, and through real-time calculation and processing of the controller ECU, combined with the calibration data written during calibration development, the current state of the engine is determined, and then the corresponding control signals are output to the actuators. During engine operation, the controller ECU can monitor the operating state in real time. If there is an abnormal signal, the corresponding fault code is reported and sent to the generator set module display screen through the CAN line. The controller can also determine whether the engine needs to be downgraded according to the fault category.

[0055] Further, the preset blending condition includes engine speed ≥ speed threshold, water temperature ≥ 65℃ and load rate ≥ preset proportion. When all conditions are met, the ECU controls the methanol pump and the methanol injector to work, and enters the diesel-methanol blending mode.

[0056] Further, the PCBA circuit board is coated with an insulating layer, the waterproof and breathable valve is arranged at the top of the upper shell for balancing the internal and external pressure and preventing liquid water from entering, and the shock pad is arranged at the bottom of the lower shell for isolating engine vibration.

[0057] Further, in the pure diesel mode, the ECU only controls the diesel injector to inject diesel; in the diesel-methanol blending mode, the ECU synchronously controls the diesel injector and the methanol injector, and the methanol injected by the methanol injector enters the combustion chamber after being atomized through the intake pipe.

[0058] Further, the abnormal signals of the fault diagnosis module include sensor signal out of range, actuator failure or methanol liquid level below threshold. When an abnormality is detected, the ECU performs the following operations according to the preset logic:

[0059] General fault: send fault code and control the engine to run at a reduced torque;

[0060] Severe fault: send fault code and control the engine to stop.

[0061] Further, the connector uses a waterproof connector, integrates the wire harness interface of the diesel injection system and the methanol injection system, and the number of wire harnesses is reduced by more than 50% compared with the traditional dual-controller scheme.

[0062] Further, the ECU is built-in equivalent fuel consumption rate calculation module, which calculates the equivalent fuel consumption rate (Cesf) in real time according to the diesel mass flow, methanol mass flow and low heat value of the two, and the formula is:

[0063] Cesf=(md+mm×Qm / Qd) / P×1000

[0064] Wherein, md is diesel mass flow (kg / h), mm is methanol mass flow (kg / h), Qm=19700kJ / kg is the low heat value of methanol, Qd=42500kJ / kg is the low heat value of diesel, P is engine power (kW).

[0065] Further, the ECU is provided with a methanol replacement rate calculation module, which calculates the methanol replacement rate (MSR) according to the diesel consumption mass flow in the pure diesel mode and the blending mode, and the formula is:

[0066] MSR= (md1-md2) / md1;

[0067] Wherein, md1 is the diesel consumption mass flow (kg / h) in the pure diesel mode,

[0068] md2 is the diesel consumption mass flow (kg / h) in the blending mode.

[0069] Further, the upper shell and the lower shell are connected by buckles or bolts, and a sealed cavity is formed inside, and the PCBA circuit board is fixed to the inner wall of the shell by heat-conducting silica gel to achieve heat dissipation and shock resistance.

[0070] Further, the controller supports connection with external calibration equipment through CAN bus to realize unified calibration and development of diesel injection parameters and methanol injection parameters by a single set of calibration tools

[0071] The working principle of the dual-fuel controller for the unit in the above embodiment is as follows:

[0072] S0: The unit display screen presses the power-on button, the controller is powered on and self-checked, if the controller ECU self-checking state is normal, S1 is executed; if the controller ECU self-checking state is abnormal, S4 is executed.

[0073] S1: The unit display screen presses the start torque, the controller ECU key switch receives the power-on signal, and the unit is started in the pure diesel mode; after the ECU unit monitors the engine state and the unit is normally preheated according to the module setting, the engine is raised to the working state, at this time the unit can run with load. The controller ECU monitors the engine state in real time, judges whether it meets the diesel-methanol blending mode, if it meets the blending condition, S2 is executed, if it does not meet the blending condition, the unit continues to run in the pure diesel mode.

[0074] S2: When the controller ECU monitors the engine speed, water temperature and load rate to meet the blending conditions, the ECU controls the methanol pump to start working. After the methanol supply system is normally built up, the pressure before the methanol injector is stabilized by the pressure relief valve, and the methanol injector is controlled to work, injecting methanol into the intake pipe. The airflow in the intake pipe carries the methanol spray into the combustion chamber for combustion. At this time, the unit is in diesel-methanol blending mode. If the ECU detects abnormal signals during unit operation, the corresponding fault code will be reported, and S4 will be executed. When the methanol level in the unit is too low or the unit needs to be shut down, S3 will be executed.

[0075] S3: When the controller ECU detects that the methanol tank level is below the threshold, the ECU will control the methanol injector to stop spraying and stop supplying power to the methanol pump. At this time, the unit switches to pure diesel mode. When the unit is normally running in diesel-methanol blending mode, the unit needs to normally shut down the load and stop. During the process of shutting down the load, the ECU detects that the load rate is less than the threshold, the blending condition is not met, and the unit switches from blending mode to pure diesel mode. After the work speed is idle and the heat is dissipated, the unit stops at idle speed.

[0076] S4: When the unit is in the power-on state, the controller ECU detects abnormal signals and sends them to the unit module in the form of fault codes. Related troubleshooting can be performed according to the fault codes. The unit needs to solve the related problems before it can start running. When the unit is running normally, the controller ECU detects abnormal signals. The ECU will determine whether the fault is serious according to the fault type. General faults will be downgraded to limited torque operation, and serious faults will be shut down for repair.

[0077] In the above embodiments and working principles,

[0078] 1. A single controller integrates diesel injection control module and methanol injection control module, replacing traditional two independent ECUs, avoiding double-controller communication compatibility problems from the source, and improving system reliability.

[0079] 2. Single set of calibration tool supports unified debugging of diesel and methanol injection parameters, significantly reducing labor costs and maintenance costs compared to traditional double-controller solutions.

[0080] 3. The ECU collects multiple parameters such as engine speed, water temperature and load rate in real time, and only starts the methanol injection system when the preset blending conditions are met, avoiding the blindness of traditional single temperature threshold control, ensuring stable operation of pure diesel during cold start, efficient switching to blending mode after warm-up, and significantly reducing diesel consumption.

[0081] 4. The built-in equivalent fuel consumption rate and methanol replacement rate calculation module optimizes fuel ratio in real time, not only reducing the fuel cost of the unit, but also meeting the stringent environmental protection requirements.

[0082] 5、Fault diagnosis module real-time monitoring sensor signal and actuator state, detect abnormal when generating fault code and through CAN bus to the unit display screen, support "general fault limit torque degradation" and "serious fault immediately stop" hierarchical processing, fault positioning accuracy, avoid the chain damage caused by a single system failure.

[0083] 6、Waterproof breather valve prevents liquid water and dust into, while balancing the internal and external pressure, auxiliary heat dissipation;Shock pad isolation engine vibration, PCBA circuit board through the heat silicone fixed and coated insulation layer, make the controller in harsh environment failure rate is reduced, the service life is prolonged.

[0084] 7、Support pure diesel mode and diesel methanol mixed mode automatic / manual switch, users can choose according to fuel supply, load demand and environmental protection requirements, improve the unit applicable scene.

[0085] In summary, the device through "hardware integration + control intelligent + diagnosis real-time" innovative design, solve the traditional dual fuel control system cost, low efficiency, poor reliability problem, in reducing fuel cost, improve environmental performance at the same time, for the intelligent control of generator set provides a standardized solution, has significant engineering application value and market competitiveness.

[0086] The above specific embodiments, the purpose, technical scheme and beneficial effects of the utility model are further described in detail, should be understood that the above is only the specific embodiment of the utility model, but the protection scope of the utility model does not limit to this, any skilled in the art of technical personnel in the utility model disclosed in the technical range, according to the technical scheme of the utility model and the utility model concept of equivalent replacement or change, should be covered in the protection scope of the utility model.

[0087] In addition, in the description of the utility model, it should be understood that the terms indicating the orientation or position relationship are based on the orientation or position relationship shown in the drawings, only for the convenience of describing the utility model and simplifying the description, and not indicating or implying that the indicated device or element must have a particular orientation, a particular orientation and operation, therefore, it cannot be understood as a limitation of the utility model.

[0088] Furthermore, in the utility model, unless another definite provision and limitation, the term " install " " link " " connect " " fixed " and so on term should do the broad sense understanding, for example, can be fixed connection, also can be detachable connection, or be integrated; can be mechanical connection, also can be electrical connection; can be directly connected, also can pass through the indirect connection of intermediate medium, can be the communication of two elements or the interaction of two elements. For ordinary skilled person in the art, the specific meaning of the above terms in the utility model can be understood according to the specific circumstances.

Claims

1. A dual fuel controller for a genset, the controller comprising: Comprise: Controller body: composed of upper shell, lower shell, PCBA circuit board, connector, waterproof breather valve and shock pad, the PCBA circuit board integrates diesel injection control module and methanol injection control module; Sensor acquisition module: through the wire harness connects the crankshaft sensor, fuel metering unit, phase sensor, water temperature sensor, intake temperature and pressure sensor, oil temperature and pressure sensor and rail pressure sensor, real-time acquisition of engine operating parameters; Actuator control module: through the wire harness connects diesel injector, methanol pump and alcohol sprayer, output control signal to adjust fuel injection; Central processing unit (ECU): electrically connected with the sensor acquisition module and actuator control module, with built-in calibration data storage unit, according to the real-time acquisition of sensor signal and the preset blending condition, control engine in pure diesel mode or diesel methanol blending mode; Fault diagnosis module: real-time monitoring of sensor signal and actuator state, when detecting abnormal, generate fault code and send to the unit module display screen through CAN bus, according to the fault level control engine degradation or shutdown.

2. The dual fuel controller for generator set according to claim 1, wherein: The preset blending condition includes engine speed ≥ idle speed threshold, water temperature ≥ 65℃ and load rate ≥ preset proportion, when meeting simultaneously, the ECU controls the methanol pump and alcohol sprayer to work, enters diesel methanol blending mode.

3. A dual fuel controller for a genset as claimed in claim 1, characterized in that: The PCBA circuit board surface is coated with an insulating layer, the waterproof breather valve is arranged at the top of the upper shell, used for balancing the internal and external pressure and preventing liquid water from entering, the shock pad is arranged at the bottom of the lower shell, used for isolating engine vibration.

4. The dual fuel controller for generator set according to claim 1, wherein: In the pure diesel mode, the ECU only controls the diesel injector to inject diesel; in the diesel methanol blending mode, the ECU synchronously controls the diesel injector and alcohol sprayer, wherein the methanol injected by the alcohol sprayer enters the combustion chamber after being atomized through the intake pipe.

5. The dual fuel controller for generator set according to claim 1, wherein: The abnormal signal of the fault diagnosis module includes sensor signal out of range, actuator failure or methanol liquid level below threshold, when detecting abnormal, the ECU performs the following operations according to the preset logic: General fault: send fault code and control engine to run with limited torque; Serious fault: send fault code and control engine to stop.

6. A dual fuel controller for a genset as recited in claim 1, characterized by: The connector adopts waterproof connector, integrates the wire harness interface of diesel injection system and methanol injection system, the number of wire harness is reduced by more than 50% compared with the traditional dual controller scheme.

7. A dual fuel controller for a genset as recited in claim 1, characterized by: The ECU is built-in equivalent fuel consumption rate calculation module, according to diesel mass flow, methanol mass flow and low heat value of the two, real-time calculates equivalent fuel consumption rate (Cesf), the formula is: Cesf=(md+mm×Qm / Qd) / P×1000 Wherein, md is diesel mass flow (kg / h), mm is methanol mass flow (kg / h), Qm=19700kJ / kg is low heat value of methanol, Qd=42500kJ / kg is low heat value of diesel, P is engine power (kW).

8. A dual fuel controller for a genset as recited in claim 1, characterized by: The ECU is internally provided with a methanol replacement rate calculation module, which calculates the methanol replacement rate (MSR) according to the diesel consumption mass flow in the pure diesel mode and the blending mode, MSR=(md1-md2) / md1; Wherein, md1 is diesel consumption mass flow (kg / h) in the pure diesel mode, md2 is diesel consumption mass flow (kg / h) in the blending mode.

9. The dual fuel controller for a genset of claim 1, wherein: The upper shell and the lower shell are connected through buckling or bolts, and a sealed cavity is formed inside, the PCBA circuit board is fixed to the inner wall of the shell through heat-conducting silica gel, and heat dissipation and shock resistance are realized.

10. The dual fuel controller for a genset of claim 1, wherein: The controller supports connection with external calibration equipment through CAN bus, and realizes unified calibration development of diesel injection parameters and methanol injection parameters by a single set of calibration tools.

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