Engine-Generator Set Self-Diagnostic Testing at Reduced Speed
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Solution Overview
Problem
Existing electrical engine-generator sets face challenges in performing diagnostic tests without producing objectionable noise levels, and the costs and expertise required for functional testing limit their usefulness and timeliness of service.
Innovation Solution
The engine-generator set performs self-diagnostic tests at reduced speeds, minimizing noise, emissions, and fuel consumption, with operating parameters compared to reference values, and alerts sent via the Internet for notification and repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If diagnostic tests are performed at full speed, then measurement precision is improved, but noise level increases to objectionable levels
Solution Approach 1:
The patent changes the operating speed parameter from full speed to reduced speed during diagnostic testing. The controller operates the engine-generator set at a reduced speed below normal operating speed during self-diagnostic tests, thereby producing less noise while still enabling effective diagnostics through comparison of operating parameters to reference values stored in memory.
2Loss of information
If expensive communication adapters are used for fault reporting, then information transmission capability is improved, but device complexity and cost increase
Solution Approach 1:
The controller performs self-diagnostic tests and self-evaluates operating parameters against reference values, storing results in memory and generating fault indicators autonomously. The system uses existing communication capabilities (modem, telephone network, Internet) rather than requiring specialized expensive communication adapters, thereby reducing device complexity while maintaining fault information transmission capability.
3Reliability
If full speed operation is used for diagnostics, then reliability assessment is improved, but fuel consumption increases
Solution Approach 1:
The operating speed parameter is changed from full speed to reduced speed during diagnostic operations. The controller operates the engine at reduced speed below normal operating speed to perform self-diagnostic tests, thereby reducing fuel consumption while still assessing system reliability through comparison of measured operating parameters to reference values stored in memory.
Data Source
AI summary
A diagnostic test is conducted by operating an engine-generator set at a plurality of reduced speeds. At each of those speeds, operating parameters of the engine are sensed and analyzed to detect an unsatisfactory operating condition. For example, such operating parameters may include speed of the engine-generator set, engine oil pressure and level, engine temperature, coolant level, and battery voltage. When a transition in engine speed occurs, a throttle test also may be conducted to measure how quickly and smoothly the engine reaches the new speed. After the engine reaches the normal operating speed, the generator is activated to produce electricity. One or more characteristic of that electricity, such as voltage, current and frequency, are sensed and evaluated to detect an unsatisfactory operating condition.