Locomotive Thermal Management via Alternator Load Control
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Solution Overview
Problem
Locomotive aftertreatment systems face challenges in maintaining minimum operating temperatures during idle conditions, leading to inefficient fuel consumption and emission reduction, as existing solutions like U.S. Pat. No. 6,422,001 may not optimally manage temperature for all devices and can result in wasteful heating.
Innovation Solution
A control system with sensors and alternators that dynamically adjust engine load by connecting alternators to power consumers to achieve and maintain the necessary temperature for aftertreatment systems, using a controller to determine the required power output and selectively engage either the first or second alternator based on available power, and shutting down the engine when auxiliary power can sustain system loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the engine runs at idle speeds for extended periods, then the locomotive avoids shutdown and maintains power to support systems, but the aftertreatment system cannot achieve minimum operating temperature and fuel efficiency deteriorates
Solution Approach 1:
The system dynamically adjusts engine load by selectively connecting alternators to power consumers based on real-time temperature conditions. When aftertreatment temperature is below threshold, the controller increases engine load by connecting alternators to power consumers, which generates additional heat. When temperature is sufficient, the system reduces load to maintain fuel efficiency. This dynamic adjustment resolves the contradiction between continuous operation and fuel efficiency.
Solution Approach 2:
The system changes the operating parameters of the engine by adjusting load levels based on aftertreatment temperature. The controller monitors temperature and modifies engine parameters (load, power output) accordingly. This parameter change enables the engine to operate at higher load when heating is needed and at lower load when temperature is sufficient, resolving the contradiction between maintaining continuous operation and preserving fuel efficiency.
2Temperature
If additional load is applied to the engine to increase aftertreatment temperature, then the temperature requirement is met, but fuel consumption increases
Solution Approach 1:
The system employs feedback control by continuously monitoring aftertreatment temperature and adjusting engine load accordingly. The controller receives temperature feedback and only increases load when temperature falls below the threshold, reducing load when temperature is sufficient. This feedback mechanism ensures load is applied only when necessary, minimizing fuel consumption while maintaining temperature requirements.
Solution Approach 2:
The system applies partial action by selectively connecting alternators to power consumers only when temperature threshold is not met, rather than continuously applying maximum load. This partial application of load reduces unnecessary fuel consumption while still achieving the required temperature increase when needed.
3Loss of energy
If the engine is shut down during idle conditions, then fuel consumption is reduced, but the aftertreatment system temperature drops below operating requirements
Solution Approach 1:
The system takes preliminary action by increasing engine load through alternator connection before temperature would naturally drop to problematic levels. By proactively managing load and temperature, the system maintains aftertreatment temperature above threshold during idle conditions, enabling fuel consumption reduction through controlled shutdowns while preventing temperature from dropping below operating requirements.
4Temperature
If the existing control system increases engine speed and load to regenerate particulate filter, then filter temperature increases, but the system is not optimal for maintaining constant temperature of other aftertreatment devices
Solution Approach 1:
The system achieves universality by implementing a general-purpose thermal management strategy that can be applied to various aftertreatment devices (particulate filters, oxidation catalysts, selective catalytic reduction systems). The controller monitors temperature of the aftertreatment system and applies load management through alternator connection that is effective for different device types, making the system adaptable and versatile across multiple aftertreatment technologies.
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
Effectively maintains aftertreatment system temperatures, reduces fuel consumption, and minimizes emissions by optimizing heat management and load distribution, ensuring efficient operation even during idle conditions.
Implementation Method 1
A control system may include a first alternator and a second alternator driven by the engine
Implementation Method 2
Many locomotives employ engines that combust fuels to generate mechanical and/or electrical power
Implementation Method 3
Typical aftertreatment systems incorporate one or more filters, catalysts, and/or other devices that utilize heat generated by the associated engine to reduce, convert, burn, or otherwise treat pollutants in the exhaust
Data Source
AI summary
A control system for a machine having an engine, a first alternator, a second alternator, and an aftertreatment system is disclosed. The control system may include a sensor associated with the aftertreatment system and configured to determine a temperature of exhaust passing through the aftertreatment system, and a controller in communication with the sensor and connectable to the first and second alternators. The controller may be configured to determine an available power output of the first alternator, determine a load increase of the engine needed to raise the temperature of the exhaust to an operating temperature of the aftertreatment system, and selectively connect the first alternator to a power consumer to achieve the load increase when the available power output of the first alternator is greater than the load increase. The controller may be further configured to selectively connect the second alternator to the power consumer to achieve the load increase when the available power output of the first alternator is less than the load increase.