Zone-Based Load Sharing for Marine Power Systems

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Solution Overview

Problem

Existing power systems in marine vessels often operate all engines at similar capacities, leading to suboptimal fuel efficiency, responsiveness, and increased emissions, and previous solutions like U.S. Patent Application Publication 2013/0342020 face delays and instability due to time-consuming load partition computations.

Innovation Solution

A power system with multiple power sources divided into zones, a load manager, and a controller that determines operational modes and selectively operates power sources within specific zones based on current demands and performance goals, allowing for dynamic adjustments to optimize fuel consumption, emissions, transient response, and engine wear.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If all engines operate simultaneously at the same capacity to evenly distribute loads, then load distribution is simplified and system stability is maintained, but fuel efficiency decreases, emissions increase, and responsiveness deteriorates

Engineering Contradiction:
Improvesystem stabilityVSAvoidfuel efficiency
Core Design Contradiction:
ReliabilityVSLoss of energy

Solution Approach 1:

The operating range of each power source is divided into multiple power zones (e.g., low-power zone, medium-power zone, high-power zone). The controller selectively operates power sources in specific zones based on total load demand, transitioning between zones as load changes. This segmentation allows the system to avoid inefficient partial-load operation while maintaining stability through controlled zone transitions.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The system dynamically adjusts the operational state of power sources based on real-time load demand. The controller monitors total load and selectively activates or deactivates power sources, transitions between power zones, and adjusts power output levels dynamically. This dynamic operation enables the system to optimize fuel efficiency across varying load conditions while maintaining reliability.

Inventive Principle:
Principle #15Dynamics

2Loss of energy

If load partition solutions are constantly computed and changed to optimize fuel consumption, then fuel efficiency improves, but system delays increase and power grid stability deteriorates

Engineering Contradiction:
Improvefuel consumptionVSAvoidsystem delays
Core Design Contradiction:
Loss of energyVSLoss of time

Solution Approach 1:

Power zones are pre-defined within the operating range of each power source before operation begins. The controller simply determines which pre-defined zone to operate in based on current load demand, rather than computing optimal partitions in real-time. This preliminary structuring eliminates time-consuming computations during operation while maintaining fuel efficiency optimization.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system uses simple, discrete power zone boundaries and straightforward transition logic instead of complex, continuously computed load partition solutions. This simplified approach reduces computational burden and system delays while achieving adequate fuel efficiency optimization through zone-based control.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

3Loss of energy

If load partition solutions are constantly computed and changed to optimize fuel consumption, then fuel efficiency improves, but power grid stability deteriorates

Engineering Contradiction:
Improvefuel consumptionVSAvoidpower grid stability
Core Design Contradiction:
Loss of energyVSStability of the object's composition

Solution Approach 1:

By dividing the operating range into discrete power zones with defined boundaries, the system creates stable operating regions. Transitions between zones are controlled and predictable, preventing the erratic power output changes that would result from constant load partition recomputation. This segmentation maintains power grid stability while achieving fuel efficiency optimization.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The controller monitors total load demand and uses this feedback to selectively operate power sources in appropriate power zones. This closed-loop control ensures that power output adjustments are coordinated and stable, preventing the instability that would arise from constant load partition changes while maintaining optimal fuel consumption.

Inventive Principle:
Principle #23Feedback

4Power

If power sources operate at high capacity to meet peak demand, then power availability improves, but fuel consumption increases and emissions increase

Engineering Contradiction:
Improvepower availabilityVSAvoidemissions
Core Design Contradiction:
PowerVSObject-generated harmful factors

Solution Approach 1:

The operating range is segmented into power zones including low-power, medium-power, and high-power zones. The controller selectively operates power sources in appropriate zones based on total load demand, avoiding unnecessary high-capacity operation. This segmentation enables the system to provide adequate power availability while minimizing emissions by operating in lower-emission zones when possible.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The system changes operational parameters (power output levels, active power source configuration) based on total load demand to optimize the power-to-emissions ratio. By dynamically adjusting these parameters and transitioning between power zones, the system maintains power availability while reducing emissions through more efficient operating points.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS9952612B2Power system having zone-based load sharing
Publication Date: 2018.04.24 CATERPILLAR INC
  • US9952612B2 patent drawing
  • US9952612B2 patent drawing
  • US9952612B2 patent drawing

AI summary

A power system is provided for a machine, such as a marine or petroleum drilling vessel. The power system may have a plurality of power sources, each with an operating range divided into a plurality of power zones. The power system may also have at least one power consumer driven by the plurality of power sources, a load manager associated with the at least one power consumer and configured to create a load demand for the plurality of power sources, and a controller in communication with the load manager and the plurality of power sources. The controller may be configured to determine a current operational mode of the power system, and to selectively cause the plurality of power sources to operate in particular zones of the plurality of power zones based on the current operational mode and the load demand.