Generator Set Fuel Injection Control for Load Transients
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Solution Overview
Problem
Existing generator sets, especially those with turbocharged engines, face performance degradation due to inadequate load regulation, leading to slow engine operation during sudden load increases, as they lack an economical means to inform the fuel injection system of the load level, resulting in transient speed fluctuations.
Innovation Solution
A method for regulating fuel injection in generator sets by using a control loop that detects load increases through electrical quantities from the alternator and substitutes sensor input values to anticipate and correct load variations before they affect engine speed, allowing for proactive fuel injection adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the fuel injection system relies on speed sensor detection to regulate load, then the system structure remains simple and economical, but the response time during load increases is delayed and performance degrades
Solution Approach 1:
The patent introduces an intermediary device (load detection device or control device) that mediates between the alternator output and the fuel injection system. This intermediary detects electrical quantities (current, voltage, power) from the alternator and converts them into load level information that the fuel injection system can use for proactive regulation, resolving the contradiction by adding a specialized intermediary component rather than complicating the entire system.
Solution Approach 2:
The patent replaces the traditional mechanical speed-sensing-based load detection with an electrical quantity-based detection system. Instead of relying solely on mechanical speed sensor feedback, the system uses electrical measurements (current, voltage, or power) from the alternator output to determine load level, enabling earlier and more accurate load detection that translates directly to fuel injection control.
2Speed
If the engine speed governor waits for speed sensor detection before increasing fuel injection, then the control loop remains stable and simple, but the engine acceleration during sudden load increase is delayed
Solution Approach 1:
The patent implements preliminary action by detecting the load level through electrical quantities before the engine speed actually drops. The fuel injection system is commanded to increase injection in advance based on the detected load level, rather than waiting for speed sensor feedback. This proactive approach accelerates engine response while the control device maintains stability by coordinating the preliminary injection increase with the alternator's electrical output characteristics.
Solution Approach 2:
The patent enhances the control loop with dual feedback mechanisms: traditional speed sensor feedback for stability and new electrical quantity feedback (current, voltage, or power) for proactive load detection. The control device synthesizes both feedback signals, using electrical feedback to trigger preliminary fuel injection increases while speed feedback ensures the control loop remains stable and coordinated.
3Power
If turbocharged engines are used to improve power output, then the power level increases, but performance degrades when turbocharging cannot start properly due to slow engine operation
Solution Approach 1:
The patent applies preliminary action by detecting the load level through electrical quantities and proactively increasing fuel injection before the engine speed drops. This ensures the turbocharged engine maintains sufficient rotational speed to keep the turbocharger operating effectively, preventing turbocharger stall or improper operation that would occur with slow engine acceleration, thereby ensuring reliable turbocharging operation at high power levels.
Data Source
Figure 1
Figure 2~4C
AI summary
The present invention relates to a method for regulating the injection of fuel into a combustion engine (2) of an electric generator set (1) comprising an alternator (3) driven by the electric motor, the electric generator set comprising at least one sensor (5) sensing the speed of the combustion engine (2) and using a control loop having at least at input a signal coming from the sensor (5), the method involving the following steps: - detecting an increase in load on the output side of the alternator (3) from at least one electrical quantity on the output side of the alternator and, - when an increase in load is detected, substituting at least one predefined value for at least one value delivered by the speed sensor (5) at input to the control loop.