Engine Speed Control Using Load Feedback in Power Systems
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Solution Overview
Problem
Conventional engine-driven systems increase engine speed to full rated speed whenever a load is applied, which can lead to inefficiencies, especially in welding loads where power requirements are difficult to accurately calculate, causing the engine to operate at higher speeds than necessary.
Innovation Solution
The system controls engine speed based on load-related factors, using a pressure transducer to monitor air pressure and incrementally adjust engine speed in response to changes in air pressure and input current, allowing for precise speed adjustments between idle and peak speeds to match load demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the engine speed is increased to full rated speed whenever a load is applied, then the power supply capability is improved, but the energy consumption increases and the engine lifespan decreases
Solution Approach 1:
The engine speed is made dynamically adjustable based on actual load conditions. The control system continuously monitors load-related factors and adjusts the engine speed accordingly, allowing it to operate at lower speeds when loads are light and at higher speeds when loads are heavy, rather than maintaining a fixed high speed.
Solution Approach 2:
The control system uses feedback from load-related factors to continuously adjust the engine speed. By monitoring the actual power demand and comparing it with the current engine output, the system can make real-time adjustments to optimize the balance between power supply capability and energy consumption.
2Power
If the engine speed is increased to full rated speed whenever a load is applied, then the power supply capability is improved, but the engine lifespan decreases
Solution Approach 1:
The engine operates dynamically at varying speeds matched to actual load requirements. This reduces unnecessary high-speed operation that causes wear and tear, thereby extending the engine's operational life while still maintaining the capability to supply required power when needed.
Solution Approach 2:
The engine speed parameter is changed based on load conditions. By adjusting this critical parameter to match actual demands, the system reduces excessive stress on the engine components during light-load operations, which helps extend engine lifespan while preserving full power capability when required.
3Speed
If the engine speed is controlled based on calculated power requirements, then the operating speed can be optimized, but the measurement precision decreases due to difficulty in accurately calculating welding loads
Solution Approach 1:
Instead of directly measuring or calculating the complex welding load parameters, the system uses intermediate indicators such as air pressure and input current as proxies to infer the actual power requirements. These intermediary measurements are more reliable and easier to obtain accurately than direct power calculations from welding parameters.
Solution Approach 2:
The system replaces the complex mechanical/electrical power calculation method with a simpler sensor-based measurement approach. By using sensors to monitor air pressure and input current, the system obtains more accurate real-time information about actual power demands without the complexities of calculating welding load from electrical parameters.
Data Source
AI summary
Methods and apparatus to control engine speed of a power system are disclosed. An example power system includes: an engine; a generator configured to generate electrical power from mechanical power delivered by the engine; a switched-mode power supply configured to convert the electrical power from the generator to output power; and control circuitry configured to: monitor an input current to the switched-mode power supply; and in response to the input current exceeding a threshold current, incrementally increasing a speed of the engine.