Asymmetric Load Distribution for Dissimilar Generator Sets

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Solution Overview

Problem

Existing methods for distributing electrical load among multiple generator sets fail to account for the different operating characteristics and response capabilities of gensets, leading to inefficiencies and potential overload during dynamic changes in power demand.

Innovation Solution

An electrical power system with an electronic controller that applies distinct operational ranges and power targets to gensets based on their individual response capabilities, allowing for asymmetrical load sharing and dynamic adjustments to meet changing power demands.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If symmetrical load sharing is used to distribute electrical load among multiple gensets, then load distribution and synchronization are achieved, but fuel efficiency and emissions are not optimized because the prime mover operating characteristics are not considered

Engineering Contradiction:
Improveload distributionVSAvoidfuel efficiency
Core Design Contradiction:
ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent implements asymmetric load sharing by assigning different operational ranges and power targets to different gensets based on their individual prime mover characteristics. Instead of treating all gensets equally, the system tailors the load distribution to match each genset's optimal operating point, thereby resolving the contradiction between achieving reliable load distribution and optimizing fuel efficiency.

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The system dynamically adjusts operational parameters (operational ranges and power targets) for each genset based on real-time conditions and prime mover characteristics. By changing these parameters asymmetrically across different gensets, the system optimizes fuel efficiency while maintaining stable load distribution, directly addressing the technical contradiction.

Inventive Principle:
Principle #35Parameter changes

2Use of energy by moving object

If asymmetric load sharing is used to optimize fuel efficiency, then prime mover operating characteristics are considered, but response capability differences among gensets are not accounted for during dynamic load changes

Engineering Contradiction:
Improvefuel efficiencyVSAvoidresponse capability
Core Design Contradiction:
Use of energy by moving objectVSAdaptability or versatility

Solution Approach 1:

The patent introduces dynamic adjustment mechanisms that allow the system to adapt to changing load conditions in real-time. The electronic controller continuously monitors load demands and adjusts operational ranges and power targets for each genset based on both their prime mover characteristics and current response capabilities. This dynamic approach resolves the contradiction by enabling the system to maintain fuel efficiency optimization while simultaneously adapting to varying response requirements.

Inventive Principle:
Principle #15Dynamics

3Ease of operation

If all gensets operate at the same percentage of their rated capacity, then symmetrical loading is achieved, but gensets with different response capabilities experience unequal stress and wear during dynamic load changes

Engineering Contradiction:
Improveoperational simplicityVSAvoidstress distribution
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The patent applies local quality by customizing operational parameters for each individual genset based on its specific characteristics, including response capability and prime mover properties. Each genset receives tailored operational ranges and power targets rather than uniform treatment, which resolves the contradiction by ensuring that stress and wear are distributed according to each unit's actual capabilities while maintaining ease of operation through automated control.

Inventive Principle:
Principle #3Local quality

Data Source

PatentUS10503132B2Load distribution for dissimilar generator sets
Publication Date: 2019.12.10 CATERPILLAR INC
  • US10503132B2 patent drawing
  • US10503132B2 patent drawing
  • US10503132B2 patent drawing

AI summary

An electrical power system includes a plurality of generator sets (gensets) having different response capabilities which are connected to a common bus that is coupled to an electrical load. The gensets may be operatively associated with one or more electronic controllers. Each genset has an operational range applied to it and a power target set for it. In the event of a change in the power demand by the electrical load, the operational ranges and the power target setting are changed according to the response capabilities of the individual gensets. To facilitate the change, the faster responding genset can operate intermittently according to various methods to generate additional power to compensate for the power deficiency of the slower responding genset as it adjusts to its changed settings.