Auxiliary Diesel Exhaust Fluid Transfer System for Generator Enclosures
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Solution Overview
Problem
Diesel engine power systems face interruptions due to insufficient capacity of on-board diesel exhaust fluid (DEF) tanks, which limits uninterrupted operation despite auxiliary fuel supplies being available.
Innovation Solution
A generator assembly system with a primary DEF tank housed in the generator enclosure and an auxiliary DEF tank in an external enclosure, connected by a transfer pump and fluid conduit, controlled by sensors and a controller to maintain optimal DEF levels, temperature, and pressure, allowing continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If the on-board DEF tank capacity is increased, then the uninterrupted operation time is improved, but the physical footprint and size of the generator enclosure increases
Solution Approach 1:
The DEF storage system is divided into two separate tanks: a primary DEF tank housed within the generator enclosure and an auxiliary DEF tank located in an external enclosure. This segmentation allows the generator to access additional DEF capacity without increasing the footprint of the generator enclosure itself, thereby extending uninterrupted operation time while maintaining a compact generator design.
Solution Approach 2:
The auxiliary DEF tank is positioned in an external enclosure separate from the generator enclosure, effectively moving the additional storage capacity to a different spatial location. This dimensional separation allows the system to access greater total DEF volume without expanding the generator enclosure's physical footprint.
2Quantity of substance
If the auxiliary DEF tank is added outside the generator enclosure, then the DEF storage capacity is improved, but the system complexity increases
Solution Approach 1:
The system incorporates sensors (level, temperature, pressure) and an automatic transfer pump that enable the DEF transfer process to occur autonomously based on monitored conditions. When the primary tank's DEF level drops below a threshold, the controller automatically activates the transfer pump to replenish it from the auxiliary tank, eliminating the need for manual intervention and reducing operational complexity despite the added hardware.
Solution Approach 2:
The system uses level sensors, temperature sensors, and pressure sensors to continuously monitor the primary DEF tank's conditions and provide feedback to the controller. This feedback mechanism enables automatic control of the transfer pump, ensuring DEF is transferred only when needed and maintaining optimal levels in the primary tank, thereby managing system complexity through intelligent control rather than manual management.
3Quantity of substance
If the transfer pump is activated frequently, then the DEF level in the primary tank is maintained, but the energy consumption increases
Solution Approach 1:
The transfer pump is activated only partially or intermittently based on the actual DEF level in the primary tank, rather than running continuously. The level sensor triggers pump activation only when the DEF level drops below a predetermined threshold, and the pump operates only long enough to replenish the primary tank to the desired level. This partial action approach maintains adequate DEF levels while minimizing unnecessary energy consumption that would result from continuous pump operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables continuous operation of diesel engines by transferring DEF from an auxiliary tank to the primary tank based on sensed parameters, ensuring uninterrupted power generation.
Implementation Method 1
A transfer pump is fluidly coupled to the auxiliary diesel exhaust fluid storage tank, and at least one fluid conduit fluidly couples the transfer pump to the primary diesel exhaust fluid storage tank
Implementation Method 2
The primary diesel exhaust fluid system may include a level sensor configured to sense a quantity of fluid in the primary diesel exhaust fluid storage tank
Implementation Method 3
The primary diesel exhaust fluid system includes a temperature sensor configured to sense a temperature value of fluid in the primary diesel exhaust fluid storage tank
Implementation Method 4
The primary diesel exhaust fluid system may include a pressure sensor configured to sense a pressure value of fluid in the primary diesel exhaust fluid storage tank
Implementation Method 5
the auxiliary diesel exhaust fluid storage tank includes a vent configured to vent the auxiliary diesel exhaust fluid storage tank to ambient air
Implementation Method 6
The vent may include a filter configured to inhibit contaminants from the ambient air from entering the diesel exhaust fluid in the auxiliary diesel exhaust fluid storage tank
Implementation Method 7
The at least one fluid conduit may also include a filter configured to inhibit contaminants in the diesel exhaust fluid from flowing through the at least one fluid conduit
Implementation Method 8
The auxiliary diesel exhaust fluid storage tank and/or the at least one fluid conduit may further include a heating system to heat the diesel exhaust fluid when the ambient temperature is cold
Implementation Method 9
In one embodiment this heating system is a heat exchanger configured to heat diesel exhaust fluid utilizing heated coolant from the diesel engine
Data Source
AI summary
Generator assembly systems and methods of manufacturing and operating generator assembly systems. The generator assembly system includes a generator enclosure, a diesel engine, an aftertreatment exhaust system, a primary diesel exhaust fluid system, and an auxiliary diesel exhaust fluid system. The primary diesel exhaust fluid system includes a primary diesel exhaust fluid storage tank fluidly coupled to the aftertreatment exhaust system. The auxiliary diesel exhaust fluid system includes an auxiliary diesel exhaust fluid storage tank and a transfer pump fluidly coupled to the auxiliary diesel exhaust fluid storage tank. The auxiliary diesel exhaust fluid system is housed in an auxiliary enclosure positioned outside of the generator enclosure. At least one fluid conduit fluidly couples the transfer pump to the primary diesel exhaust fluid storage tank.