Generator Set Load Control Using Jacket Water Heating
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Solution Overview
Problem
Generator set engines experience adverse effects such as wet stacking and increased oil consumption when operated in no load or low load conditions, and aftertreatment components like DPFs can lose efficiency or malfunction due to insufficient mechanical load and low ambient temperatures.
Innovation Solution
A control system monitors engine parameters to automatically add a supplemental electrical load using an electric jacket water heater with a resistive load, which supplements the external electrical load during no load, low load, or low ambient temperature conditions to improve engine efficiency and thermal management of aftertreatment components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the generator set operates in no load or low load conditions, then the electrical output to external load is reduced, but the engine experiences wet stacking and increased oil consumption
Solution Approach 1:
The patent introduces a heating system with electric fluid heater as an intermediary component that converts electrical energy to thermal energy to heat the engine coolant. This mediator allows the system to maintain engine temperature and prevent wet stacking during low load operation, bridging the gap between reduced electrical output and engine reliability
Solution Approach 2:
The heating system uses the generator set's own electrical output to power the electric fluid heater, allowing the system to self-regulate and maintain proper operating conditions without external intervention. The heater automatically activates when load is low to prevent engine damage
2Productivity
If the generator set operates in no load or low load conditions, then the electrical output to external load is reduced, but oil consumption increases
Solution Approach 1:
The heating system acts as an intermediary that converts electrical energy to thermal energy to maintain engine operating temperature. By preventing the engine from operating too cold, the system reduces oil consumption that would otherwise occur during low load conditions
Solution Approach 2:
The system uses its own electrical output to power the heater, creating a self-regulating mechanism that automatically reduces oil consumption when load is low without requiring external control or intervention
3Productivity
If the generator set operates in low ambient temperature conditions, then the electrical output to external load is maintained, but aftertreatment components like DPF lose efficiency or malfunction
Solution Approach 1:
The heating system serves as a mediator between the engine and aftertreatment components, using electric heating of the coolant to maintain proper temperatures in the exhaust system. This ensures DPF and other aftertreatment components operate efficiently even in cold ambient conditions
Solution Approach 2:
The system changes the temperature parameter of the engine coolant by activating the electric fluid heater. This parameter change ensures that aftertreatment components receive sufficiently hot exhaust gases to maintain their efficiency and prevent malfunction during cold operation
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 solution effectively prevents wet stacking and oil consumption issues while maintaining the efficiency and functionality of aftertreatment components by ensuring sufficient mechanical load and thermal management, even during extended operation in low load conditions.
Implementation Method 1
the heating system including an electric fluid heater, wherein the electric jacket fluid includes a resistive load
Data Source
AI summary
A generator set configured to provide an electrical output to an external electrical load. The generator set includes an engine configured to drive an electric generator, the engine including an engine block, where the electric generator is configured to couple to the external electrical load. The generator set includes a heating system in fluid communication with the engine block, the heating system including an electric fluid heater, where the electric jacket fluid includes a resistive load configured to supplement the external electrical load. The generator set includes a control system for: monitoring a first parameter of the engine; generating a first control signal in response to the first parameter being less than a first threshold; and increasing the external electrical load by turning on the electric fluid heater in response to the first control signal.