Dual Fuel Engine Virtual Sensor Using Temperature Differential

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Solution Overview

Problem

Dual-fuel engines, particularly those using diesel and natural gas, face challenges in determining the energy content of natural gas, which can lead to premature engine failure and reduced lifespan due to unpredictable energy variability, necessitating a system to monitor and account for energy levels.

Innovation Solution

A system comprising a fuel description module and a control circuit that utilizes intake and exhaust manifold temperature sensors to calculate the total energy content of fuel supplied to the engine, allowing for precise energy determination and adjustment to prevent overloading.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the engine rating is set at an artificially low level to prevent exceeding capacity due to fuel energy variability, then engine reliability is improved, but productivity deteriorates because the engine cannot be fully utilized under normal fueling conditions

Engineering Contradiction:

Improveengine reliabilityVSAvoidengine utilization

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system employs feedback by continuously monitoring exhaust gas temperature and using it to determine the actual energy content of the fuel. This information feeds back to the control circuit, which then adjusts fueling decisions to keep the engine within its rated capacity. This resolves the contradiction by enabling dynamic adaptation to fuel variability rather than using a static conservative rating.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system changes the parameter of engine operation by dynamically adjusting fueling based on determined energy content. When high energy content fuel is detected through exhaust temperature monitoring, the system reduces fueling to prevent exceeding rated capacity. When lower energy content fuel is detected, the system increases fueling to maintain optimal operation. This resolves the contradiction by allowing full engine utilization while preventing overload through real-time parameter adjustment.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If fueling decisions are made without knowing the energy content of natural gas, then device complexity is reduced, but measurement precision deteriorates because the energy content of fuel cannot be determined

Engineering Contradiction:

Improvesystem complexityVSAvoidenergy content determination

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The system uses the engine's own exhaust gas temperature as a self-service indicator of fuel energy content. Rather than requiring external complex measurement equipment to analyze fuel composition, the system leverages the natural thermal signature of combustion to determine energy content. This resolves the contradiction by providing accurate energy measurement through a simple, already-present sensor.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system replaces complex chemical analysis mechanisms with a simpler thermal measurement approach. Instead of using sophisticated equipment to directly measure the energy content or composition of natural gas, the system uses temperature sensing of exhaust gas to infer energy content. This substitution maintains measurement precision while significantly reducing device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 accurate monitoring and management of energy input, preventing engine overload and extending engine lifespan by ensuring operation within rated capacity, while allowing for full utilization under normal fueling conditions.

Implementation Method 1

The system comprises a fuel description module and a control circuit that utilizes intake and exhaust manifold temperature sensors to calculate the total energy content of fuel supplied to the engine

Methodology Applied

Scientific EffectTemperature measurement:

Implementation Method 2

A system comprising a fuel description module and a control circuit that utilizes intake and exhaust manifold temperature sensors to calculate the total energy content of fuel supplied to the engine

Methodology Applied

Scientific EffectTemperature measurement:

Implementation Method 3

A system comprising a fuel description module and a control circuit that utilizes intake and exhaust manifold temperature sensors to calculate the total energy content of fuel supplied to the engine

Methodology Applied

Scientific EffectEnergy calculation from temperature differential:

Data Source

PatentUS10132250B2Exhaust parameter based dual fuel engine power virtual sensor

Publication Date: 2018.11.20 CUMMINS INC

AI summary

The system comprises a fuel description module structured to provide a first signal, and a control circuit operable to receive the first signal. The fuel description module comprises a fuel consumption detection package. The fuel consumption detection package an intake manifold temperature sensor and an exhaust temperature sensor, wherein the first signal corresponds to a difference between the exhaust manifold temperature (EMT) and the intake manifold temperature (IMT). The control circuit is responsive to the first signal to produce a second signal indicating a total energy content (Efuel) of fuel supplied to the dual-fuel engine. The Efuel value indicating the total energy content provided to the engine from a first fuel and a second fuel.