Hybrid Generator-Battery Power Conversion for Wet Stacking Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Diesel engines coupled to generators are susceptible to wet stacking and inefficiency when lightly loaded, leading to increased fuel consumption and emissions.
Innovation Solution
A hybrid energy system that manages the operational environment of engine-driven generators by storing excess power in a battery bank, allowing the generator to run at optimal load and reducing runtime, thus eliminating light loading and wet stacking issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a load bank is applied to increase the load on the generator, then wet stacking is prevented, but fuel consumption increases significantly
Solution Approach 1:
The system dynamically adjusts the generator load by connecting or disconnecting the battery bank based on actual power demand. When real load is minimal, the battery absorbs excess power to maintain optimal generator loading without requiring a fixed load bank. This dynamic adjustment prevents wet stacking while avoiding continuous excessive fuel consumption.
Solution Approach 2:
The system changes the operating parameters of the generator by varying the electrical load through battery charging/discharging cycles. The controller monitors power demand and adjusts the battery connection state to maintain generator output within the optimal loading range (30-70% capacity), thereby preventing wet stacking conditions without sustained high fuel consumption.
2Use of energy by moving object
If the generator runs at optimal load to improve efficiency, then fuel consumption per kwh decreases, but runtime increases due to inability to power down
Solution Approach 1:
The system employs periodic charging and discharging cycles of the battery bank. When the generator produces excess power beyond immediate load requirements, the battery charges. When the battery is sufficiently charged, the generator can be shut down periodically, and the battery supplies power to the load during these intervals. This periodic operation reduces overall generator runtime while maintaining fuel efficiency during active periods.
Solution Approach 2:
The battery bank serves as an intermediary energy storage device between the generator and the load. It decouples the generator operation from immediate load requirements, allowing the generator to run at optimal load for charging the battery, then power down when the battery can sustain the load. This intermediary enables runtime reduction without compromising load supply.
3Use of energy by moving object
If the generator is shut down to reduce runtime, then fuel consumption decreases, but the load cannot be powered when power is needed
Solution Approach 1:
The system performs preliminary action by charging the battery bank during periods when the generator is operational and power demand is low. The battery is charged in advance to sufficient levels so that when the generator shuts down, the load can be continuously powered from battery storage. This preliminary energy accumulation ensures reliability during generator downtime.
Solution Approach 2:
The battery bank enables continuous power supply to the load even when the generator is shut down. The system maintains uninterrupted useful action (power supply) by transitioning from generator-powered operation to battery-powered operation seamlessly. The controller manages the transition to ensure continuous load coverage, maintaining reliability while reducing generator runtime.
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 hybrid energy system minimizes engine/generator run hours, improves fuel consumption, and reduces emissions by ensuring the generator operates at optimal load and powers down when not needed, utilizing battery storage to supply power.
Implementation Method 1
storing unused power, or power the generator is capable of producing that is more than the load requires, in a battery
Implementation Method 2
A DC/DC converter adjusts (raises or lowers) the voltage output of the battery bank to a desired DC voltage that is applied to a DC bus
Implementation Method 3
An AC/DC converter receives and converts an AC voltage from the generator to a DC voltage that is applied to the DC bus
Implementation Method 4
A DC/AC converter converts the DC voltage from the DC bus to an AC voltage that is applied to an AC outlet panel
Data Source
AI summary
A hybrid energy system is configured to carry a power load for a generator configured to output a first AC signal. The hybrid energy system includes a battery bank, a DC/DC converter, an AC/DC converter, and a DC/AC converter. The battery bank includes a plurality of batteries and outputs a first DC signal. The DC/DC converter, operating in a first mode, receives and converts the first DC signal into a second DC signal, which is output to a DC bus. The AC/DC converter receives and converts the first AC signal into a third DC signal. The second DC signal and the third DC signal are tied together on the DC bus. The DC/AC converter receives and converts the second DC signal from the DC bus into a plurality of second AC signals, which are output to an AC outlet interface.