Engine Overspeed Protection via Air Intake Gas Detection

Solution Overview

Problem

Current engine overspeed protection systems are inadequate in detecting and responding to anomalous events, often resulting in catastrophic failures due to their limited range and reactivity, leading to damage and safety hazards, as exemplified by incidents like the Texas City refinery explosion and Deepwater Horizon disaster.

Innovation Solution

A system that detects explosive or flammable gases in the incoming air stream of engines, sending a shutdown signal before an overspeed condition occurs, utilizing gas sensors and communication networks to actuate valves and control systems, allowing for proactive engine shutdown and preventing damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional RPM-based sensors are used to detect overspeed conditions, then the system responds to anomalous events, but the response occurs too late to prevent catastrophic damage

Engineering Contradiction:

Improveengine safetyVSAvoidresponse time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The gas detection system performs preliminary monitoring of the incoming air stream for explosive or flammable gases before the engine can develop an overspeed condition. By detecting the presence of combustible gases that could cause runaway combustion, the system triggers a shutdown signal in advance, preventing the overspeed event before it occurs rather than reacting after RPM sensors detect the problem.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces gas sensors as an intermediary detection mechanism between the potential hazard (combustible gases in air intake) and the engine. This intermediary system provides early warning of dangerous conditions by monitoring gas concentrations, allowing the control system to intervene before the actual overspeed damage occurs, bridging the gap between hazard presence and protective action.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If manual activation or pre-set RPM triggers are used for shutdown, then the device can be activated, but the engine is rendered unusable due to seal damage and destructive events

Engineering Contradiction:

Improvesafety shutdownVSAvoidengine usability

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The gas detection system performs preliminary monitoring of the incoming air stream for explosive or flammable gases before the engine can develop an overspeed condition. By detecting the presence of combustible gases that could cause runaway combustion, the system triggers a shutdown signal in advance, preventing the overspeed event before it occurs rather than reacting after RPM sensors detect the problem.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors gas concentrations in the air intake and provides real-time feedback to the control system. When combustible gas levels reach dangerous thresholds, the feedback loop triggers an automatic shutdown signal, creating a closed-loop safety system that responds proportionally to the detected hazard level rather than using fixed pre-set RPM triggers.

Inventive Principle:

Principle #23Feedback

3Speed

If abrupt air shutoff is used to stop an overspeeding engine, then the engine stops, but seals are pulled out and destructive events occur

Engineering Contradiction:

Improveengine speed reductionVSAvoidseal integrity

Core Design Contradiction:

SpeedVSStrength

Solution Approach 1:

The gas detection system performs preliminary monitoring of the incoming air stream for explosive or flammable gases before the engine can develop an overspeed condition. By detecting the presence of combustible gases that could cause runaway combustion, the system triggers a shutdown signal in advance, preventing the overspeed event before it occurs rather than reacting after RPM sensors detect the problem.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system provides beforehand cushioning by detecting dangerous gas concentrations and triggering a controlled shutdown sequence before the engine can enter a destructive overspeed state. This preventive approach cushions against the potential damage by eliminating the hazard (combustible gas mixture) before it can cause runaway combustion and seal failure, rather than attempting to stop an already-overspeeding engine.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

The system effectively prevents engine overspeed and subsequent damage by detecting gas concentrations and species, enabling timely shutdowns even before critical levels are reached, thereby enhancing safety and reducing the risk of catastrophic events.

Implementation Method 1

detecting a concentration of an explosive or flammable gas in an incoming air stream to an engine

Methodology Applied

Scientific EffectGas detection:

Data Source

PatentUS10851728B2Engine overspeed device and method

Publication Date: 2020.12.01 KANARY ALERT SYSTEMS LLC

AI summary

Methods, systems and devices for evaluating incoming air to an engine for concentrations of explosive or combustible gases, and shutting down the engine to prevent an overspeed condition when elevated concentrations are detected. In some embodiments engine shutdown may be achieved conventionally via an electronic kill signal and in emergency conditions by the shutoff of incoming air to an air intake. The ability to make decisions based on explosive gas concentrations and species and the use of networking to allow additional systems to take action even before explosive gases reach said other valve-sensor devices can provide additional safety.