Genset Controller Custom Sensor Calibration

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Solution Overview

Problem

Genset controllers often struggle to properly process data from replacement or optional sensors with different output characteristics, leading to sub-optimal performance, unnecessary alarms, and compromised efficiency and emissions, as they are typically pre-configured with hard-coded sensor maps that do not accommodate changes in sensors.

Innovation Solution

A method and system that allows for the configuration of a genset controller to process inputs from both standard and custom sensors by using a data processor with a writable medium to store custom sensor calibration data, enabling users to input custom sensor map data, including minimum, maximum, and additional map values for accurate signal processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If genset controllers use hard-coded sensor maps for standard sensors, then the controller is pre-configured and reliable for standard operation, but it cannot properly process data from replacement or optional sensors with different output characteristics

Engineering Contradiction:

Improvesensor compatibilityVSAvoidcontroller configuration

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The controller is pre-configured with default sensor maps for standard sensors during manufacturing. This preliminary configuration ensures reliable standard operation while allowing users to later input custom calibration data for replacement or optional sensors through a user interface, thus maintaining adaptability without requiring complex reconfiguration from scratch

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system allows users to modify sensor calibration parameters by inputting custom minimum, maximum, and map values for replacement or optional sensors. This parameter change capability enables the controller to adapt to different sensor output characteristics while maintaining the overall controller architecture and operation

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If manufacturers write custom software fixes for each sensor replacement, then the controller can accommodate specific sensor changes, but the process is time-consuming and requires extensive software modifications

Engineering Contradiction:

Improvesensor replacement capabilityVSAvoidconfiguration time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system enables end-users to perform sensor calibration configuration themselves through an intuitive user interface. Users can directly input custom sensor calibration data (minimum values, maximum values, and map values) without requiring manufacturers to write custom software fixes, thus eliminating time-consuming software modification processes while maintaining full sensor replacement capability

Inventive Principle:

Principle #25Self-service

3Productivity

If the controller uses fixed sensor calibration data, then the processing is simple and fast, but it leads to sub-optimal sensor data processing and unnecessary alarms when replacement sensors are used

Engineering Contradiction:

Improvedata processing speedVSAvoidsensor data accuracy

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system transitions from static hard-coded sensor maps to dynamic configurable calibration data. The controller maintains simple and fast processing by using lookup tables for sensor calibration, but these tables become dynamically adjustable when users input custom minimum, maximum, and map values for replacement sensors, thus ensuring both processing speed and data accuracy

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS7509221B2Custom configuration strategy for on-package genset controllers

Publication Date: 2009.03.24 CATERPILLAR INC

AI summary

A method of setting up a genset system for operation includes selecting one of a plurality of different sensors to monitor an operating parameter of a genset system, and coupling the selected sensor with a data processor of the genset system. The method further includes configuring the data processor for processing inputs from the selected sensor, for example an optional replacement sensor, by entering custom sensor calibration data for the selected sensor and recording the custom sensor calibration data on at least one computer writable medium of a control system for the genset system. A genset system includes a combustion engine, a generator, a set of standard sensors, and a control system. The control system includes a data processor configured to receive and process inputs from custom sensors, and includes a computer writable medium for storing custom sensor calibration data.