Dynamic Cool-Down Timer for Backup Generator Controllers

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Solution Overview

Problem

Existing backup generator systems often result in unnecessary extended runtimes and excessive fuel costs due to fixed cool-down timers, which do not account for varying load conditions and environmental factors, leading to unnecessary engine wear and inefficiency.

Innovation Solution

A system and method that utilize a controller to determine a cool-down time based on the load history and environmental conditions, allowing the generator to cool down only after primary power is restored, thereby optimizing engine wear and fuel efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a fixed cool-down timer is used regardless of load conditions, then the generator is ensured to cool down adequately, but unnecessary extended runtimes occur leading to excessive fuel costs and engine wear

Engineering Contradiction:

Improveadequate coolingVSAvoidfuel cost

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The cool-down timer is changed from a fixed static value to a dynamic value that adjusts based on real-time load conditions. The controller monitors the load history and calculates an optimized cool-down time that is sufficient for adequate cooling but minimized to avoid unnecessary fuel consumption and engine wear.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The cool-down time parameter is changed from a constant fixed value to a variable parameter that changes based on load conditions. The system monitors load magnitude and duration, then adjusts the cool-down timer parameter accordingly to optimize the balance between adequate cooling and fuel efficiency.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If a fixed cool-down timer is used, then cooling adequacy is maintained, but unnecessary engine wear occurs due to extended runtime

Engineering Contradiction:

Improveadequate coolingVSAvoidengine runtime

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The engine runtime during cool-down is dynamically adjusted based on load conditions. The controller monitors the generator's operational history and adjusts the cool-down duration to be the minimum necessary time for adequate cooling, thereby reducing unnecessary engine runtime and wear.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The cool-down duration parameter is changed from a fixed constant to a variable that changes based on load magnitude and duration. This allows the system to minimize engine runtime while ensuring adequate cooling by adjusting the parameter according to actual operational conditions.

Inventive Principle:

Principle #35Parameter changes

3Loss of energy

If the generator cools down immediately after primary power is restored, then fuel efficiency is improved, but inadequate cooling occurs leading to engine damage

Engineering Contradiction:

Improvefuel efficiencyVSAvoidengine protection

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The system uses feedback from load monitoring to determine the appropriate cool-down duration. The controller continuously monitors load conditions and uses this feedback to calculate the minimum necessary cool-down time that ensures adequate engine cooling while minimizing fuel consumption and improving efficiency.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary monitoring of load conditions before determining the cool-down duration. By analyzing the load history in advance, the controller can pre-calculate the optimized cool-down time that balances engine protection with fuel efficiency, avoiding both inadequate cooling and excessive runtime.

Inventive Principle:

Principle #10Preliminary action

4Measurement precision

If a thermal sensor is used to detect cooling status, then precise cooling monitoring is achieved, but system cost and complexity increase due to additional components

Engineering Contradiction:

Improvecooling status detectionVSAvoidsystem components

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces the thermal sensor-based mechanical/physical detection system with a computational system. Instead of using additional hardware sensors to detect cooling status, the controller uses software-based algorithms that monitor load history and calculate cooling status and optimized cool-down time, thereby reducing system complexity and component costs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system creates a computational model or representation of the cooling process based on load history data. Rather than physically sensing temperature, the controller uses a mathematical model that copies the essential characteristics of the cooling process to determine adequate cool-down time, avoiding the need for additional thermal sensors.

Inventive Principle:

Principle #26Copying

Data Source

PatentUS9853494B2Active engine cool down time delay for automatic transfer switch controllers

Publication Date: 2017.12.26 EATON INTELLIGENT POWER LTD

AI summary

A system for providing backup power to a facility includes a generator and a controller. The controller is configured to operate the generator until a condition is met, determine a load history that occurs while operating the generator until the condition is met, determine a cool-down time based on the determined load history, and run the generator to the point when the condition is met and in an unloaded condition for the cool-down time.