Load Bank Control for Diesel Generator Wet Stacking

Solution Overview

Problem

Diesel engine-generators operating under lightly loaded conditions face issues with wet stacking and soot buildup, which can lead to clogged particulate filters, and existing load bank systems are wasteful in terms of fuel consumption.

Innovation Solution

A load bank system with variable resistance load resistors and controllers that monitor engine and generator loads to maintain a minimum load, reducing regeneration frequency and ensuring efficient DPF regeneration by maintaining optimal exhaust temperatures, while minimizing fuel usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a dummy load bank is connected to maintain minimum generator loading, then wet stacking and soot buildup are reduced, but fuel consumption increases

Engineering Contradiction:

Improveengine operation reliabilityVSAvoidfuel consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The controller continuously monitors generator load and automatically engages or disengages load bank resistors based on real-time load conditions, ensuring the dummy load is only applied when necessary to prevent wet stacking, thus optimizing fuel consumption while maintaining engine reliability

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The load bank system dynamically adjusts its resistance values and engagement state based on varying generator load conditions, transitioning between engaged and disengaged states to match actual operational needs, reducing unnecessary fuel consumption while preventing engine damage

Inventive Principle:

Principle #15Dynamics

2Object-generated harmful factors

If regeneration is performed to clean DPF, then soot accumulation is removed, but engine operability decreases during regeneration

Engineering Contradiction:

Improvesoot accumulationVSAvoidengine operability

Core Design Contradiction:

Object-generated harmful factorsVSEase of operation

Solution Approach 1:

The controller proactively monitors soot accumulation levels and initiates regeneration cycles before the DPF becomes completely blocked, and simultaneously engages the load bank to maintain minimum generator loading, ensuring regeneration can proceed effectively without severely impacting engine operability

Inventive Principle:

Principle #10Preliminary action

3Use of energy by moving object

If generator operates under lightly loaded conditions, then fuel consumption decreases, but wet stacking and soot buildup increase

Engineering Contradiction:

Improvefuel consumptionVSAvoidengine operation reliability

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The controller continuously monitors generator load and automatically engages or disengages load bank resistors based on real-time load conditions, ensuring the dummy load is only applied when necessary to prevent wet stacking, thus optimizing fuel consumption while maintaining engine reliability

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The load bank system dynamically adjusts its resistance values and engagement state based on varying generator load conditions, transitioning between engaged and disengaged states to match actual operational needs, reducing unnecessary fuel consumption while preventing engine damage

Inventive Principle:

Principle #15Dynamics

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 decreases the frequency of regeneration cycles, maintains efficient DPF regeneration, and reduces fuel consumption by only engaging the load bank when necessary to prevent wet stacking and soot buildup.

Implementation Method 1

such schemes tend to be wasteful because they cause the engine portion of the engine-generator to burn a set amount of fuel, at all times, in order to maintain PG

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

a lightly loaded, diesel-fueled engine-generator may cause the engine portion of the machine to operate such that fuel within the engine remains unburned

Methodology Applied

Scientific EffectCombustion: Combustion

Implementation Method 3

Modern diesel engines, including so-called Tier IV Interim and newer engines, are equipped with particulate filters that serve to capture and remove soot from engine exhaust

Methodology Applied

Scientific EffectPhysical filtration: Filter (physical)

Implementation Method 4

Regeneration involves a process in which the engine doses a DPF with diesel and then ignites that diesel to burn-off accumulated soot

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS20140239921A1Engine-generator with load bank and control system

Publication Date: 2014.08.28 MULTIQUIP INC

AI summary

A load bank comprises one or more load resistors connected to an engine-generator and a control system for maintaining a minimum generator load when necessary for optimal operation. The control system operates the load bank to mitigate harmful effects of generator neglect and maintains loading for efficient DPF regeneration while allowing the generator to quickly dump the load bank when real load increases.