A thermal management system

Abstract

The invention relates to a thermal management system designed for use in generators with diesel or gas-fueled engines. The system is positioned between the radiator and the block water heater (pot tank) and / or between the pot tank and the engine jacket water inlet. Instead of operating the circulation pumps continuously, the system intermittently activates them at specific time intervals. This allows for homogeneous heat distribution within the engine jacket and prevents unnecessary heating of areas outside the engine jacket, thereby improving energy efficiency.

Description

[0001] A THERMAL MANAGEMENT SYSTEM

[0002] TECHNICAL FIELD

[0003] The invention relates to a thermal management system designed for use in generators with diesel or gas-fueled engines. The system is positioned between the radiator and the block water heater (pot tank) and / or between the pot tank and the engine jacket water inlet. Instead of operating the circulation pumps continuously, the system intermittently activates them at specific time intervals. This allows for homogeneous heat distribution within the engine jacket and prevents unnecessary heating of areas outside the engine jacket, thereby improving energy efficiency.

[0004] BACKGROUND

[0005] Diesel or gas-fueled engines used in generator sets are internal combustion engines that convert mechanical energy into electrical energy by transmitting it to the generator shaft. While these engines operate based on fundamentally similar working principles, they exhibit distinct characteristics due to the type of fuel they use and the differences in their combustion processes.

[0006] Diesel engines operate with a compression-ignition structure. During the working cycle, only air is drawn into the engine cylinder, and this air is compressed by the upward movement of the piston. As a result of the compression, the temperature of the air rises significantly. Into this high-temperature air, diesel fuel is injected through the fuel system. Due to the high temperature inside the cylinder, the diesel fuel ignites spontaneously, initiating combustion. During combustion, the pressure generated by the expanding gases pushes the piston downward, thereby rotating the crankshaft and producing mechanical energy. Diesel engines are generally known for their ability to generate high torque, durability, and their advantage of long-term operation under heavy loads.

[0007] In gas-fueled engines, fuels such as natural gas, LPG, or biogas are used, and these engines operate with a spark ignition system. During operation, a mixture of air and gas fuel is drawn into the engine cylinder and is compressed to a high pressure by the movement of the piston. The compressed mixture is then ignited by a spark generated by the spark plug. The combustion resulting from ignition pushes the piston downward, and the crankshaft is rotated to transfer energy to the generator shaft. Gasengines offer advantages such as being environmentally friendly, producing lower emissions, and operating more quietly.

[0008] In both types of engines, the upward and downward movement of the pistons is transmitted to the crankshaft, and this motion rotates the generator shaft to produce electrical energy. The type of engine is selected based on the area in which the generator will be used and the specific energy requirements.

[0009] According to the information provided by engine and generator manufacturers, for diesel or gas-fueled engines in generator sets to operate properly and be able to handle the load at startup, the jacket water temperature must be at least +40°C or higher before ignition. The jacket refers to the structure in engines consisting of channels or chambers surrounding the cylinder block through which the coolant circulates. It is used to control the heat generated during engine operation and ensures that the engine runs at an optimal temperature by preventing overheating. The fluid inside the jacket is typically a mixture of antifreeze and water, which facilitates the transfer of heat away from the engine. In order for engines and generators to operate efficiently, the jacket water temperature must be at least +40°C before starting. This requirement is critical for ensuring optimal engine performance and long-term durability. Maintaining this temperature helps the engine safely handle the initial load during startup and minimizes the risk of wear and damage.

[0010] The primary reason for maintaining the jacket water temperature above +40°C is to bring the engine's moving parts and fuel system to optimal operating conditions. At low temperatures, engine oil becomes more viscous and cannot reach the moving components quickly enough. This can lead to wear and premature degradation of critical parts such as the crankshaft, pistons, and bearings, especially during start-up. Additionally, in diesel engines, low temperatures can hinder proper atomization of the fuel, resulting in irregular combustion, delayed engine start, or rough and unstable engine operation.

[0011] Under low temperature conditions, issues can also arise in the fuel injection system. Specifically, in diesel engines, cold weather can cause diesel fuel to thicken or form paraffin crystals, which may clog the injection system. This can result in the engine failing to start or producing insufficient power even if it does start. In gas engines, lowtemperatures make it difficult to form a proper air-fuel mixture, leading to inefficient spark ignition.

[0012] Another significant issue is the potential damage to the engine block and cooling system components due to sudden temperature changes. In a cold engine, the rapid increase in temperature caused by combustion can create thermal stress, increasing the risk of cracks in the engine block and cylinder head. Moreover, engines operating at low temperatures tend to produce higher emissions, as the combustion process is incomplete, leading to an increased release of environmentally harmful gases.

[0013] As a result, the +40°C jacket water temperature specified by engine and generator manufacturers is a critical precaution to prevent engine wear, improve fuel efficiency, and ensure reliable performance during the initial start-up. Therefore, especially in cold weather conditions, the engine’s jacket water should be brought to the specified temperature level using jacket water heaters or heating systems.

[0014] In existing generator sets (typically 500 kVA and above), the radiator and pot tank (block water heater) are critical components for regulating the engine’s cooling and operating temperature. The radiator helps dissipate excess heat from the coolant while the engine is running, ensuring that the engine operates at its optimal temperature. The pot tank, on the other hand, heats the coolant before the engine is started in order to raise the jacket water temperature to the desired level (+40°C and above). This allows the engine to handle the initial load more easily and reduces the risk of wear. In generator sets of 500 kVA and above, a circulation pump is installed either between the radiator and the pot tank or between the pot tank and the engine jacket water inlet to ensure effective transfer of the heated water from the pot tank to the engine jacket and to achieve a homogeneous heat distribution within the engine jacket. This pump forcibly directs the heated coolant into the engine jacket, enabling uniform heat distribution throughout the engine block.

[0015] In the systems known in the prior art, the circulation pump operates continuously. The continuous operation of the circulation pump results in a constant flow of jacket water. This causes certain areas outside the engine jacket to be unnecessarily heated, accelerates the cooling of the heated jacket water, and leads to energy loss. For example, when the circulation pump runs continuously, the water heated in the pot tank is rapidly transferred not only to the engine jacket but also to the radiator. Consequently, the already heated coolant cools down more quickly in theradiator and its associated components. Moreover, due to the continuous flow, components outside the engine block — such as connection points near the radiator or peripheral cooling pipes — are also unnecessarily heated. This redundant heat transfer causes the engine and other equipment to cool down more rapidly, triggering the heater to operate again to reheat them. As a result, the system’s energy consumption increases unnecessarily. For instance, while it is only necessary to raise the engine jacket temperature to +40°C before starting the engine, the continuous operation of the circulation pump also leads to heating of the radiator and other surrounding cooling lines.

[0016] AIM OF THE INVENTION

[0017] The aim of the invention is to provide energy efficiency in diesel and gas-powered generator sets by ensuring homogeneous heat distribution within the engine jacket and preventing unnecessary heating of components outside the engine jacket. This is achieved by intermittently operating the circulation pumps — rather than running them continuously — by installing them between the radiator and the block water heater (pot tank) and / or between the pot tank and the engine jacket water inlet.

[0018] LIST OF FIGURES

[0019] Figure 1. Schematic representation of the generator set to which the system of the invention is to be applied

[0020] Equivalents of the numbers in the figures:

[0021] 1. Radiator

[0022] 2. Generator Engine

[0023] 3. Alternator

[0024] 4. Return line from radiator to engine

[0025] 5. Supply line from engine to radiator

[0026] 6. Circulation pump

[0027] 7. Heater tank

[0028] 7.1. Heater inlet

[0029] 7.2. Heater outlet

[0030] 8. Temperature sensor / Thermostat

[0031] 9. Engine block jacket circuit inlet10. Control system

[0032] DETAILED DESCRIPTION OF THE INVENTION

[0033] In a generator set, a radiator (1), a generator engine (2), and an alternator (3) are interrelated critical components that ensure the efficient operation of the system. The generator engine (2) is an internal combustion engine that produces mechanical energy through fuel combustion. During this process, the heat generated is regulated by the cooling system to prevent the engine from overheating. The radiator (1) dissipates excess heat from the engine coolant, which is transported via the supply line from engine to radiator (5) and returns the cooled coolant back to the engine through the return line from radiator to engine (4), thus maintaining optimal engine temperature. The alternator (3) converts the mechanical energy produced by the engine into electrical energy. Through this relationship, the generator set is able to produce electricity both reliably and efficiently. The radiator (1) is responsible for cooling the generator engine (2), thereby indirectly supporting the continuous power generation of the alternator (3). In this context, the invention relates to a thermal management system configured to be positioned between the radiator (1) and the generator engine (2) of a generator set. The mentioned thermal management system is an electronic circuit board that processes data received from various components of the generator set in order to improve efficiency. All technical effects generated by the electronic circuit board are enabled by a processor it contains.

[0034] In generator sets, a temperature sensor or thermostat (8) is typically located at the engine block jacket circuit inlet (9). For the technical effects of the invention to be realized, the system continuously receives data from this temperature sensor / thermostat (8). The water temperature data circulating inside the generator engine (2), obtained through the temperature sensor or thermostat (8), is transferred to a processor included in the invention. The ideal operating temperature range for generator engines is between 38 and 45 degrees Celsius. At this point, the processor checks whether the temperature information obtained from the temperature sensor or thermostat (8) falls within this range. The mentioned temperature range does not directly contribute to the technical effect of the invention; in other words, this range may vary. What is essential for the invention is the presence of a lower temperature limit and an upper temperature limit.In generator sets, it has previously been mentioned that the water circulating inside the engine block jacket circuit is heated by a heater tank (7). When the data received from the temperature sensor or thermostat (8) by the control system (10) of the generator set falls below 38°C, the relay of the heater tank (7) is activated, thus enabling the water circulating in the block jacket circuit to enter through the heater inlet (7.1), to be heated by the resistance inside the heater tank (7), and to exit through the heater outlet (7.2) and rejoin the generator system. When the water temperature reaches 45°C, the relay of the heater tank (7) is deactivated again by the control system (10), thereby switching it off. This operating logic is included in the state of the art. Regardless of the stage of this cycle — whether the water temperature is below 38°C or has reached 45°C — the circulation pumps (6) in the state of the art remain continuously active. That is, irrespective of the water temperature, the water continues to circulate within the generator block jacket circuit.

[0035] Within the above-defined system, the invention is positioned between the circulation pump (6) and the heater tank (7) of the generator set. In generator sets with more than one circulation pump (6) and / or heater tank (7), the system according to the invention can be positioned between any one or both of these. The system subject to the invention is connected to the relay or contactor of the circulation pump (6) at its installed location. Another connection is made with the temperature sensor or thermostat (8) present in the system. Thus, the system becomes capable of receiving temperature data from the temperature sensor or thermostat (8). When the temperature data received from the temperature sensor or thermostat (8) falls below 38°C (i.e., the lower limit of generator operating temperature), the processor within the system according to the invention activates the relay or contactor of the circulation pump (6), thereby enabling power flow. When power is supplied, the circulation pump (6) starts operating and initiates the flow of water into the generator block jacket circuit. Once the heater tank (7) is activated by the generator’s control unit (10), the water pumped into the system by the circulation pump (6) is heated and begins to warm up the generator engine (2).

[0036] When the temperature sensor or thermostat (8) measures a water temperature of 45°C (i.e., the upper limit of the generator operating temperature), and this measurement is received by the processor of the system subject to the invention, the processor deactivates the relay or contactor of the circulation pump (6). Thus, the power supply to the circulation pump is cut off. With the interruption of the powersupply, the circulation pump (6) stops operating and ceases to deliver water to the generator block jacket circuit. This allows the generator engine (2) to cool down naturally. In other words, in the absence of the heater tank (7), which is deactivated after reaching 45°C, the circulation of unheated and cooling water in the generator block jacket circuit is prevented, thereby avoiding the rapid cooling of the generator engine (2).

[0037] In a configuration where the circulation pump (6) in the system does not have a relay or contactor and is directly connected to the system according to the invention, the processor in the system directly cuts off the power to the circulation pump (6) and stops it or supplies power to operate it. The technical effect here lies in the processor of the system being activated to stop or operate the circulation pump (6) based on the temperature data provided by the temperature sensor or thermostat (8). Thus, it prevents the cooled water, which is not heated by the heater tank (7), from circulating and accelerating the cooling of the generator block jacket circuit.

Claims

CLAIMS1. A thermal management system to be placed between a radiator (1) and a generator engine (2) of a generator set, characterized in that it comprises an electronic board including a processor connected to the relay or a contactor of a circulation pump (6), said processor being configured to activate the relay or contactor of the circulation pump (6) when the water temperature circulating inside the generator engine (2), received from a temperature sensor / thermostat (8) located within the generator set, falls below the lower limit of the generator operating temperature, and to deactivate the relay or contactor of the circulation pump (6) when the temperature exceeds the upper limit of the generator operating temperature.

2. A thermal management system to be placed between the radiator (1) and the generator engine (2) of a generator set, characterized in that it comprises an electronic board including a processor configured to supply electrical power to the circulation pump (6) when the water temperature circulating inside the generator engine (2), received from the temperature sensor / thermostat (8) located within the generator set, falls below the lower limit of the generator operating temperature, and to cut off the electrical power to the circulation pump (6) when the temperature exceeds the upper limit of the generator operating temperature.

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