Flameless Heater Startup Control to Reduce Warm-Up Time
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Solution Overview
Problem
Conventional flameless heater systems take a considerable amount of time to reach operating temperatures, making them unsuitable for time-dependent heating applications due to the delay in producing full capacity heated air flow and the cooling effect of the air mover on the engine block during startup.
Innovation Solution
The implementation of an independent heating system, air system, hydraulic system, speed system, braking system, and temperature system, controlled by a central control system that monitors and adjusts various parameters to reduce the time needed to generate heated air, allowing for controlled airflow and hydraulic fluid flow to prevent cooling of the engine block before reaching operating temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flameless heater systems are used, then heat can be provided in hazardous conditions, but the system takes considerable time to reach operating temperatures
Solution Approach 1:
The control system performs preliminary actions by delaying the startup of the air mover until the engine block and fluids have reached sufficient operating temperature. This prevents the air mover from cooling the engine block during the warm-up phase, thereby reducing the time to reach operating temperatures while maintaining safe operation in hazardous conditions
2Productivity
If the air mover is operated during engine warm-up, then air flow is distributed, but the air mover cools the engine block and delays reaching operating temperatures
Solution Approach 1:
The system performs preliminary heating of the engine block and fluids before activating the air mover. The control system monitors temperature parameters and only enables the air mover once the engine block has reached sufficient temperature, thereby preventing premature cooling and reducing overall startup time
Solution Approach 2:
The control system dynamically adjusts the operation sequence based on real-time temperature measurements. The air mover operation is made conditional on engine block temperature, creating a dynamic system that adapts its behavior to maintain optimal temperature during the warm-up phase
3Device complexity
If hydraulic fluid flow is not regulated, then the system is simpler, but more time is needed for the fluid to reach operational conditions
Solution Approach 1:
The control system performs preliminary regulation of hydraulic fluid flow to optimize heat transfer efficiency during the warm-up phase. By controlling the flow rate of hydraulic fluid through the engine block, the system accelerates the warming process without requiring complex additional hardware
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
This solution significantly reduces the time required for the flameless heater system to reach operating temperatures, enhancing its performance and suitability for various processes by maintaining consistent air temperature despite changes in operating conditions.
Implementation Method 1
an internal combustion engine to drive a pump and fan
Implementation Method 2
The pump may be configured to move a hydraulic fluid through the engine block
Implementation Method 3
The heated fluid is then transferred from the reservoir to a heat exchanger, where the heat is extracted from the heated fluid
Implementation Method 4
an air mover (e.g., a fan) to move air from the heater assembly
Data Source
AI summary
The flameless heater system includes an energy source comprising a diesel engine configured to create volumes of air, a hydraulic system to control engine loading for heat generation and for air moving, and a control system, operatively coupled with the energy source and the hydraulic system to control at least one of a speed of the diesel engine, a loading of the diesel engine, or a fan speed.