Engine-Driven Power Load Prioritization to Prevent Stall

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Solution Overview

Problem

Conventional engine-driven power systems lack the ability to dynamically manage load priorities, leading to inefficient reduction of outputs when the total load exceeds the engine's capacity, as they are programmed with fixed orders based on anticipated user preferences.

Innovation Solution

The engine-driven power systems allow operators to specify load management priorities through a user interface, enabling control over the folding back of power subsystems based on configurable rankings, balance ratios, and voltage bus limits, thereby optimizing output reduction strategies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional engine-driven power systems use fixed order load reduction based on anticipated user preferences, then the system structure is simple, but the adaptability to different user needs and operating conditions is poor

Engineering Contradiction:
Improveload management flexibilityVSAvoidcontrol system complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements dynamic load management by allowing operators to configure priority rankings of different power subsystems through a user interface. The control circuitry dynamically adjusts which subsystems are reduced or shut down based on real-time operator preferences and system conditions, rather than following a fixed predetermined order. This enables the system to adapt to different operating scenarios and user needs.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The system incorporates feedback mechanisms where the control circuitry continuously monitors the operational status of multiple power subsystems and compares the total power demand against available engine capacity. Based on this feedback and the configured priority rankings, the control circuitry makes real-time decisions about which subsystems to reduce or shut down, creating a closed-loop control system that responds to actual system conditions.

Inventive Principle:
Principle #23Feedback

2Power

If the engine capacity is exceeded by total power subsystem demand, then more power can be delivered to subsystems, but the engine may stall

Engineering Contradiction:
Improvetotal power outputVSAvoidengine stall prevention
Core Design Contradiction:
PowerVSReliability

Solution Approach 1:

The control circuitry proactively monitors the total power demand from all subsystems and compares it against the engine's available capacity before the engine becomes overloaded. When the demand approaches or exceeds capacity, the system preemptively reduces or shuts down lower-priority subsystems according to the configured priority rankings, preventing the engine from stalling while maximizing power delivery to critical subsystems.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system changes operational parameters by dynamically adjusting the power output levels of individual subsystems based on priority rankings. When engine capacity is exceeded, the control circuitry modifies the operating parameters of selected subsystems (reducing power or shutting down) to bring the total demand within available capacity, thereby maintaining engine reliability while optimizing power distribution.

Inventive Principle:
Principle #35Parameter changes

3Reliability

If fold back circuit reduces load to match engine power, then engine overload is prevented, but the power delivery to subsystems is reduced

Engineering Contradiction:
Improveengine overload protectionVSAvoidpower delivery to subsystems
Core Design Contradiction:
ReliabilityVSPower

Solution Approach 1:

Instead of uniformly reducing power to all subsystems, the patent applies local quality by selectively reducing or shutting down specific subsystems based on their priority rankings. The control circuitry identifies which subsystems are lowest priority and targets them for reduction, while maintaining full power delivery to higher-priority subsystems. This selective approach protects the engine from overload while maximizing power delivery to critical functions.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent segments the power subsystems into different priority groups, allowing independent control of each segment. The control circuitry evaluates each subsystem's priority ranking and independently decides whether to reduce or maintain its power level. This segmentation enables intelligent power management where the engine is protected from overload through selective subsystem reduction, while critical subsystems continue to receive adequate power.

Inventive Principle:
Principle #1Segmentation

Data Source

PatentUS12306600B2Engine-driven power systems having load management prioritization
Publication Date: 2025.05.20 ILLINOIS TOOL WORKS INC
  • US12306600B2 patent drawing
  • US12306600B2 patent drawing
  • US12306600B2 patent drawing

AI summary

An example engine-driven power system includes: an engine; a generator configured to convert mechanical engine power to electrical power; first and second power subsystems configured to convert the mechanical or electrical power to first and second power outputs, wherein the first and second power subsystems are configurable to output the first and second power outputs simultaneously; an input device configured to control a load management priority, wherein the load management priority comprises at least one of an adjustable ranking, an adjustable balance, or bus voltage thresholds; and control circuitry configured to: control the first and second power subsystems to output the first and second power outputs based on first and second demands; and, in response to determining that a total demand exceeds a capacity, control the first or second power subsystems to reduce the power outputs or the demands based on the load management priority.