Generator Set Fuel Transfer Control via Segmented Tank Architecture

Solution Overview

Problem

Fuel transfer systems for electric power generator sets face challenges in efficient fuel management, particularly when the primary fuel tank is separate from the genset, leading to fueling issues due to long-distance fuel transport and inefficient fuel distribution across multiple machines.

Innovation Solution

An electric generator set fuel control system that includes a fuel level sensor, operator input devices for fuel loading and mode selection, and a control module to generate and transmit fuel transfer signals, enabling selective fuel transfer between a primary and supplemental tank through a fuel pump, optimizing fuel distribution and management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the primary fuel tank is separate from the genset, then the genset can be set up on-site and hooked to an already existing fuel tank, but fueling problems occur due to long-distance fuel transport

Engineering Contradiction:

Improveon-site setup flexibilityVSAvoidfuel supply reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The fuel system is divided into a mobile fuel tank (separate from the genset) and a fixed fuel tank (integral to the genset). The mobile tank can be positioned close to the genset for easy on-site setup, while the fixed tank provides reliable, long-term fuel storage. The fuel pump enables selective transfer between these segmented tanks, resolving the contradiction between setup flexibility and fuel supply reliability.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the primary fuel tank is integral to the genset, then fuel supply reliability is improved, but the genset cannot be easily moved or set up on-site

Engineering Contradiction:

Improvefuel supply reliabilityVSAvoidon-site setup flexibility

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The fuel system is divided into a mobile fuel tank (separate from the genset) and a fixed fuel tank (integral to the genset). The mobile tank can be positioned close to the genset for easy on-site setup, while the fixed tank provides reliable, long-term fuel storage. The fuel pump enables selective transfer between these segmented tanks, resolving the contradiction between setup flexibility and fuel supply reliability.

Inventive Principle:

Principle #1Segmentation

3Quantity of substance

If fuel is transferred from a distant tank, then fuel availability is maintained, but fuel waste increases due to long-distance transport

Engineering Contradiction:

Improvefuel availabilityVSAvoidfuel waste

Core Design Contradiction:

Quantity of substanceVSLoss of substance

Solution Approach 1:

The fuel system is divided into a mobile fuel tank (separate from the genset) and a fixed fuel tank (integral to the genset). The mobile tank can be positioned close to the genset for easy on-site setup, while the fixed tank provides reliable, long-term fuel storage. The fuel pump enables selective transfer between these segmented tanks, resolving the contradiction between setup flexibility and fuel supply reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The control module continuously monitors fuel levels in both tanks and automatically controls the fuel pump to transfer fuel from the mobile tank to the fixed tank when the mobile tank is low. This feedback mechanism ensures efficient fuel management, minimizes fuel waste, and maintains fuel availability without requiring excessive transfer distances.

Inventive Principle:

Principle #23Feedback

4Productivity

If multiple supplemental fuel tanks are used, then fuel distribution efficiency is improved, but system complexity increases

Engineering Contradiction:

Improvefuel distribution efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The control module serves multiple functions: it monitors fuel levels in both tanks, controls the fuel pump operation, and provides user interface for manual control. This multi-functional design improves fuel distribution efficiency while minimizing system complexity by consolidating control functions into a single device.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 system ensures efficient fuel transfer and management, preventing fueling problems by allowing automatic or manual control of fuel movement based on tank levels, reducing fuel waste, and enhancing operational efficiency by allowing on-site setup and convenient fuel access.

Implementation Method 1

a fuel pump configured to selectively receive or supply fuel from the first fuel tank to the second fuel tank

Methodology Applied

Scientific EffectPump: Pump

Data Source

PatentUS8950446B2Geneset fuel transfer system and method

Publication Date: 2015.02.10 CATERPILLAR INC

AI summary

An electric generator set fuel control system is disclosed. The fuel control system includes an electric generator, a prime mover mechanically coupled to the generator, a first fuel tank, a fuel level sensor configured to generate a fuel level signal indicative of a fuel level in the first fuel tank, a fuel loading operator input device configured to generate a fuel loading signal, a fueling mode operator input device configured to generate a fueling mode signal, and a control module. The first fuel tank is configured to supply fuel to the prime mover, and selectively receive or supply fuel to a second fuel tank through a fuel pump. The control module is configured to generate a fuel transfer signal as a function of the fuel loading signal, the fueling mode signal, and the fuel level signal.