Prime Mover Load Sensing Power Management

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Solution Overview

Problem

Prime movers, such as small engines, are prone to overload when driving multiple loads like electrical generators, hydraulic pumps, and air compressors, leading to reduced fuel efficiency and increased pollutant emissions, as existing solutions either severely limit individual load outputs or are sensitive to RPM feedback and not effective with modern zero drop control systems.

Innovation Solution

A power management system utilizing direct load sensing feedback from the prime mover, combined with RPM feedback and individual output load sensing, to control output loads and set the primary power source's RPM set-point, preventing overload by adjusting engine parameters and load outputs to match the prime mover's capabilities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the engine drives multiple loads simultaneously, then the service pack can provide multiple functions (electrical power, hydraulic power, compressed air), but the engine is prone to overload which reduces fuel efficiency and increases emissions

Engineering Contradiction:

Improvemulti-function capabilityVSAvoidfuel efficiency

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The system continuously monitors engine load through direct load sensing feedback and compares it against the engine's maximum capacity. When the combined load approaches the engine's limit, the controller automatically reduces or shuts off non-critical loads to prevent overload, thereby maintaining fuel efficiency while allowing multi-function operation.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system dynamically adjusts the operation of individual loads based on real-time engine load conditions. The controller can selectively engage or disengage loads (electrical generator, hydraulic pump, air compressor) depending on available engine capacity, enabling the system to adapt its output mix to match available power and optimize fuel efficiency.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If the engine drives multiple loads, then the service pack provides comprehensive power services, but the possibility of engine overload increases

Engineering Contradiction:

Improvepower service coverageVSAvoidengine overload prevention

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The system proactively prevents engine overload by continuously monitoring the sum of individual load demands against the engine's maximum capacity before overload occurs. The controller anticipates potential overload conditions and pre-emptively adjusts load allocation, rather than reacting after overload has already happened.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Direct load sensing feedback provides real-time information about the actual load on the engine, which is combined with RPM feedback and individual output load sensing. This comprehensive feedback loop enables the controller to make informed decisions about load management to maintain reliable operation within engine capabilities.

Inventive Principle:

Principle #23Feedback

3Reliability

If existing solutions limit individual load outputs to prevent overload, then engine overload is reduced, but the service pack's output capability is severely restricted

Engineering Contradiction:

Improveengine overload reductionVSAvoidload output capability

Core Design Contradiction:

ReliabilityVSPower

Solution Approach 1:

Instead of statically limiting individual load outputs, the system dynamically allocates engine capacity among multiple loads based on real-time conditions. The controller can flexibly adjust which loads are active and at what power levels, allowing the service pack to deliver high power when the engine has available capacity while preventing overload when capacity is constrained.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes operational parameters (load engagement status, power output levels) based on engine load conditions. By varying these parameters dynamically rather than maintaining fixed limits, the service pack can maximize its power delivery capability while adapting to prevent engine overload.

Inventive Principle:

Principle #35Parameter changes

4Device complexity

If existing solutions rely on RPM feedback for load control, then the control mechanism is simple, but it is not effective with modern zero drop control systems

Engineering Contradiction:

Improvecontrol mechanism simplicityVSAvoidcompatibility with modern control systems

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The system uses direct load sensing feedback that measures actual engine load independent of RPM changes. This approach is compatible with modern zero drop control systems because it directly senses load conditions rather than inferring them from RPM variations, which may not reflect actual load changes in systems with advanced governors that maintain constant RPM.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS8261717B2Service pack power management

Publication Date: 2012.09.11 ILLINOIS TOOL WORKS INC

AI summary

A power management system, in certain aspects, may utilize direct load sensing feedback from the prime mover (e.g., engine), thereby reducing the possibility of overloading the prime mover. The use of direct load sense feedback from the prime mover can then be used with additional feedback, such as prime mover RPM feedback and individual output load sensing feedback, to directly control the output loads and set the primary power sources rpm set-point to better manage the power available and reduce the possibility of overloading the primary power source.