Shovel Engine Control via Generator Load
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Solution Overview
Problem
Existing shovel technologies face challenges in maintaining engine revolution speed and reducing fuel consumption when hydraulic loads suddenly increase, leading to inefficient engine output and increased fuel consumption.
Innovation Solution
A control method for a shovel that involves increasing the electric generation load of a generator connected to the internal-combustion engine before a hydraulic load increases, using a motor generator to apply a load on the engine and maintain revolution speed, thereby preventing a drop in engine output and fuel efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the supercharge pressure is increased after detecting the increase of hydraulic load, then the engine output can be increased, but the engine revolution speed decreases and fuel consumption increases
Solution Approach 1:
The control part increases the electric generation load of the generator before the hydraulic load increases. This preliminary action causes the engine output to increase in advance, allowing the engine to maintain constant revolution speed when the hydraulic load suddenly increases, thereby avoiding excessive fuel consumption while ensuring sufficient power supply.
Solution Approach 2:
The generator acts as an intermediary load that can be controlled to adjust engine output. By controlling the electric generation load, the system can pre-increase engine output without directly increasing hydraulic load, enabling smooth transition when hydraulic load changes occur.
2Speed
If the fuel injection amount is greatly increased to maintain engine revolution speed, then the engine output can be maintained, but fuel consumption increases significantly
Solution Approach 1:
The system pre-increases engine output by controlling the generator load before hydraulic load increases. This allows the engine to maintain constant revolution speed without requiring a great increase in fuel injection amount, as the power demand is already elevated by the generator load.
Solution Approach 2:
The control part changes the operating parameters of the engine by adjusting the electric generation load. This parameter change enables the engine to operate at higher output levels proactively, maintaining revolution speed stability while optimizing fuel consumption through controlled parameter adjustment rather than reactive fuel injection increases.
3Productivity
If the engine output is increased rapidly by increasing supercharge pressure, then the power response is improved, but the engine revolution speed drops before the supercharge pressure takes effect
Solution Approach 1:
The control part increases the electric generation load before the hydraulic load increases, which proactively raises the engine output. This preliminary action ensures that when the hydraulic load suddenly increases, the engine is already operating at higher output levels, preventing revolution speed drops and maintaining power supply stability.
Solution Approach 2:
The control part monitors the hydraulic load and engine operating conditions, and adjusts the electric generation load accordingly. This feedback mechanism ensures that the engine output is adjusted in real-time to maintain constant revolution speed, improving power response while preventing speed fluctuations.
Data Source
AI summary
A shovel includes an internal combustion engine, a hydraulic pump connected to the internal-combustion engine, a generator connected to the internal-combustion engine, and a control part that controls the generator. The control part increases an electric generation load of the generator before a hydraulic load of the hydraulic pump increases.