Engine Speed Control for Turbocharger Exhaust Temperature Management

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Solution Overview

Problem

Existing engine and turbocharger systems face issues with high exhaust gas temperatures leading to undesirable side effects such as material creep and wear, which are difficult to manage due to the costly and manual process of adjusting compressor components.

Innovation Solution

A system and program product that uses a sensor to determine exhaust gas temperature and a controller to adjust engine speed based on temperature thresholds, ensuring the temperature remains within a safety window to prevent damage and optimize performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If exhaust gas temperature is increased to improve engine power output, then engine performance is improved, but turbocharger component damage risk increases due to creep and wear

Engineering Contradiction:

Improveengine power outputVSAvoidturbocharger component reliability

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The system continuously monitors exhaust gas temperature via a temperature sensor and feeds this information back to the controller. The controller automatically adjusts engine speed based on the temperature feedback, reducing engine speed when temperature exceeds the safety window and maintaining optimal speed when temperature is within acceptable ranges. This closed-loop feedback mechanism resolves the contradiction by dynamically balancing power output against component reliability based on real-time temperature conditions.

Inventive Principle:

Principle #23Feedback

2Reliability

If exhaust gas temperature is reduced by lowering engine load to protect turbocharger components, then component reliability is improved, but engine power output decreases

Engineering Contradiction:

Improveturbocharger component reliabilityVSAvoidengine power output

Core Design Contradiction:

ReliabilityVSPower

Solution Approach 1:

The system dynamically adjusts engine speed based on real-time exhaust gas temperature conditions rather than maintaining a fixed operating point. The controller continuously modifies engine speed within the safety window, allowing the system to operate at higher speeds (and thus higher power output) when temperatures are acceptable, and automatically reduces speed only when temperature thresholds are exceeded. This dynamic adaptation resolves the contradiction by optimizing power output within reliability constraints.

Inventive Principle:

Principle #15Dynamics

3Reliability

If manual adjustment of compressor pockets is performed to reduce exhaust gas temperature, then turbocharger reliability is improved, but operational complexity and cost increase

Engineering Contradiction:

Improveturbocharger reliabilityVSAvoidcompressor adjustment ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system performs self-regulation of exhaust gas temperature through automatic engine speed control. The temperature sensor and controller work together to autonomously monitor and adjust operating conditions, eliminating the need for manual intervention in compressor pocket adjustments. The system serves itself by automatically detecting temperature deviations and correcting them through engine speed modulation, thereby resolving the contradiction between reliability improvement and operational ease.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system replaces manual mechanical adjustment of compressor pockets with an automated electronic control system. Instead of physically adjusting compressor components, the controller electronically modulates engine speed based on temperature sensor feedback. This substitution of mechanical adjustment with electronic control resolves the contradiction by maintaining turbocharger reliability while dramatically improving ease of operation.

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

Effectively controls exhaust gas temperature, preventing damage and optimizing engine and turbocharger performance by automatically adjusting engine speed in response to temperature variations, thus reducing the risk of creep and wear.

Implementation Method 1

a sensor configured to determine a temperature of the exhaust gas

Methodology Applied

Scientific EffectTemperature sensing: Thermocouple

Implementation Method 2

controlling the temperature of exhaust gas yielded from an engine system and provided to a turbocharger system... preventing damage... by automatically adjusting engine speed in response to temperature variations

Methodology Applied

Scientific EffectThermal management: Heat Sink

Data Source

PatentUS9850841B2System and program product for controlling exhaust gas temperature of engine system

Publication Date: 2017.12.26 AI ALPINE US BIDCO INC

AI summary

Aspects of the disclosure include a system for controlling an exhaust gas communicated from an engine system to a turbine component of a turbocharger system. The system can include an engine having an operational speed; a turbocharger system including a turbine component, the exhaust gas being output from the engine in an exhaust line; a controller in communication with the engine; and a sensor disposed in the exhaust line being in communication with the controller, the system operating according to the following method: measuring the first temperature of the exhaust gas, determining if the measured first temperature of the exhaust gas is within a temperature safety window of the system; calculating an engine speed of the engine; and adjusting an engine speed setpoint and speed of the engine based on the measured first temperature and the calculated engine speed.