Genset Controller Using Alternator Electrical Output for Load Sensing
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Solution Overview
Problem
Conventional gensets face challenges in maintaining efficient exhaust system performance due to rapid load transitions and fluctuations, leading to undesirable NOx spikes in exhaust gases, which negatively impact emission control and system efficiency.
Innovation Solution
A genset monitoring and control system that uses an alternator's electrical output to determine mechanical load and generate engine control responses to adjust the operation of systems like EVAP, EGR, SAI, and aftertreatment systems, allowing for near-instantaneous sensing and control of engine performance and emission reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional mechanical or electrical load monitoring is used to measure engine performance, then performance measurement is achieved, but rapid load transitions and fluctuations cause NOx spikes and reduce exhaust system efficiency
Solution Approach 1:
The patent replaces conventional mechanical load monitoring systems with an electrical sensing system that uses the alternator's electrical output to determine mechanical load. The controller interprets electrical signals from the alternator to sense engine load conditions, enabling near-instantaneous detection of load transitions without the lag inherent in mechanical sensing systems. This electrical substitution allows for real-time control adjustments that prevent NOx spikes during rapid load changes.
2Reliability
If conventional control systems are used to manage exhaust components, then basic emission control is achieved, but there is insufficient responsiveness to rapid load changes leading to emission spikes
Solution Approach 1:
The patent implements a closed-loop feedback control system where the controller continuously monitors electrical output from the alternator to determine current mechanical load, compares it against desired operating parameters, and automatically adjusts exhaust system components (EGR valve, SAI system, aftertreatment doser) in real-time. This feedback mechanism enables the system to respond immediately to load transitions, maintaining reliable emission control without the delays characteristic of conventional open-loop or mechanically-based control systems.
3Object-generated harmful factors
If stringent emission requirements are enforced, then emission standards are met, but system complexity increases due to multiple control systems (EVAP, EGR, SAI, aftertreatment)
Solution Approach 1:
The patent integrates multiple exhaust control functions (EVAP, EGR, SAI, aftertreatment) into a single unified control system managed by one controller that uses a common sensing mechanism (electrical output from alternator). This multi-functional integration allows the system to meet stringent emission requirements for multiple pollutants (NOx, CO, HC, PM) simultaneously while reducing overall system complexity compared to having separate independent control systems for each function. The controller coordinates all exhaust-related components through a centralized electrical control architecture.
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 approach enables near-instantaneous adjustment of genset components to maintain performance and reduce pollutants like NOx, CO, HC, and PM, improving exhaust system efficiency and compliance with stringent emission standards.
Implementation Method 1
an alternator, and an exhaust system structured to reduce the exhaust gas. The genset further comprises a controller which is configured to: (a) interpret an electrical output from the alternator
Data Source
AI summary
A genset comprises an engine; an alternator, an exhaust system, a controller, and at least one of an intake system, an EVAP system, a fuel injector, an EGR system, a SAI system and an aftertreatment system. The controller is configured to control at least a portion of the genset. The controller is in electrical communication with one or more of the alternator, the EVAP system, the EGR system, the SAI system and the aftertreatment system via communication circuitry. Furthermore, the controller is configured to: (a) receive an electrical output from the alternator via the communication circuitry, (b) determine a load on the alternator from the electrical output, which corresponds to mechanical load on the engine, and (c) generate an electrical signal configured to at least partially control operation of at least one of the EVAP system, the EGR system, the SAI system and the aftertreatment system via the communication circuitry.