Fuel System Automatic Switching Controller

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Solution Overview

Problem

Conventional fuel switching techniques in prime movers are time-consuming and require manual intervention, lacking automatic switching capabilities between primary and secondary fuels without shutting down the system, especially when primary fuel availability is disrupted.

Innovation Solution

A fuel system with a controller that determines operating conditions, including pressure thresholds and speed values, to automatically switch between primary and secondary fuels, ensuring seamless transitions without downtime or performance impact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If conventional fuel switching techniques are used, then fuel availability can be maintained, but the process is time-consuming and requires manual intervention

Engineering Contradiction:

Improvefuel switching automationVSAvoidfuel switching time

Core Design Contradiction:

Extent of automationVSLoss of time

Solution Approach 1:

The system automatically monitors fuel pressure levels and executes fuel switching operations without manual intervention. The controller continuously compares primary and secondary fuel pressures against predetermined thresholds and autonomously actuates valves to switch fuel sources, eliminating the need for operator involvement in the monitoring and switching process.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system employs continuous feedback through pressure sensors that monitor both primary and secondary fuel pressures in real-time. The controller receives this feedback, compares the pressures against stored threshold values, and adjusts valve positions accordingly, creating a closed-loop control system that automatically responds to fuel availability conditions.

Inventive Principle:

Principle #23Feedback

2Reliability

If conventional fuel switching techniques are used, then fuel availability can be maintained, but system downtime occurs and performance is impacted

Engineering Contradiction:

Improvesystem continuityVSAvoidsystem performance

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system performs preliminary actions by pre-positioning the secondary fuel valve and maintaining it in a ready state before the primary fuel becomes unavailable. The controller continuously monitors pressure conditions and has the secondary fuel pathway prepared in advance, allowing for immediate switching without shutting down the prime mover or interrupting power generation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The fuel switching process is designed to maintain continuous operation of the prime mover. By coordinating valve actuation timing with the running conditions of the engine, the system ensures that fuel supply is continuously available without interruption, thereby maintaining both system reliability and productivity throughout the switching transition.

Inventive Principle:

Principle #20Continuity of useful action

3Extent of automation

If manual fuel switching is used, then control over fuel selection is maintained, but human intervention and potential errors increase

Engineering Contradiction:

Improvefuel switching controlVSAvoidoperational simplicity

Core Design Contradiction:

Extent of automationVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #25Self-service

4Loss of time

If automatic fuel switching is implemented, then downtime is reduced, but system complexity increases

Engineering Contradiction:

Improvefuel switching downtimeVSAvoidfuel system complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The controller serves multiple functions within the fuel system: it monitors primary and secondary fuel pressures, compares them against stored threshold values, determines when switching is appropriate, and actuates the necessary valves. This multi-functionality consolidates what would otherwise require separate components, reducing overall system complexity while achieving automatic switching capability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses changes in pressure parameters as the trigger for automatic switching. By monitoring pressure levels and comparing them against predetermined thresholds stored in the controller, the system automatically detects when fuel conditions require switching and executes the transition based on these parameter changes, simplifying the control logic.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS11885269B1Fuel system for prime mover

Publication Date: 2024.01.30 CATERPILLAR INC

AI summary

A fuel system for a prime mover includes a controller including at least one processor to determine a primary pressure value for a primary fuel, determine a secondary pressure value for a secondary fuel, and perform a first switch from the primary fuel to the secondary fuel if the primary pressure value is lesser than a first lower pressure threshold value, the secondary pressure value is greater than a second upper pressure threshold value, an operating speed value of the prime mover is greater than a fuel type initialization speed threshold value for the prime mover, an absolute speed error value is lesser than a steady-state absolute speed error threshold value for the prime mover, an operating load to be applied on the prime mover is greater than a rated load of the secondary fuel, and a fuel switchover timer threshold duration from a previous fuel switching event has elapsed.