The present disclosure relates to starting power systems, and, more particularly, to a control strategy and system for starting power systems having multiple generator units and for automatically using air and electric starters.
Power systems may have multiple generator units for supplying electricity to one or more electric power loads. For example, a multi-engine generator set switcher locomotive may include three power modules. Each power module includes an internal combustion engine associated with each generator unit. The engines may be started by various starting systems, such as an air start system and an electric start system. An electric start system may draw electric power from an electric source on the locomotive, such as a battery bank or from other engines already running, for example. An air start system may draw compressed air from an onboard compressed air source, such as a compressed air tank, for example. The compressed air source is used to provide compressed air for starting rotation of the crankshaft of the engine.
An air start system, however, may be ineffective for starting an engine if the amount of compressed air provided by the compressed air source is less than what is required to start the engine. Moreover, an electric start system may increase wear associated with the electric power source and with an associated starter motor.
An example of an air start system for using compressed air to start an engine is described in U.S. Pat. No. 4,324,212 (the '212 patent), issued on Apr. 13, 1982 in the name of Samuel et al. and assigned to Rederiaktiebolaget Nordstjernan of Sweden and Oy Wartsila A B of Finland. An example of an electric start system for use on an engine is described in U.S. Pat. No. 4,543,923 (the '923 patent), issued on Oct. 1, 1985 in the name of Hamano et al. and assigned to Mitsubishi Denki Kabushiki Kaisha. U.S. Pat. No. 4,235,216 (the '216 patent), issued on Nov. 25, 1980 in the name of Miles discloses an electric start system with a pneumatically actuated auxiliary start system.
Although the '212 patent and the '923 patent disclose an air start system and an electric start system, respectively, for starting an engine, the efficacy of the systems is limited. For example, nowhere does the '923 patent disclose using a compressed air source to start the engine and nowhere do the '212 patent and the '216 patent disclose an electric start system which starts the engine if the air start system fails. The '212, '923, and '216 patents show that air start and electric start systems are known. Modern locomotives and industrial gas turbine engines are known which have both electric and air start mechanisms. However, none of these automatically coordinate a choice between electric or air start.
The disclosed strategy and system is directed to overcoming one or more of the problems set forth above.
In one aspect, the present disclosure is directed toward a power system including at least one power module; a compressed air source in communication with the power module; an electric power source in communication with the power module; and a control module in communication with the power module, the compressed air source, and the electric power source, the control module configured to command the compressed air source to provide compressed air to the power module when the compressed air source is in a first state and to command the electric power source to provide electric power to the power module when the compressed air source is in a second state.
In another aspect, the present disclosure is directed toward a method of starting an engine, the method including the steps of measuring a pressure of compressed air in a compressed air source; if the measured pressure of compressed air is in a first state, using the compressed air to turn a compressed air-powered starter motor to start the engine; and if the measured pressure of compressed air is in a second state, using electric power to turn an electric-powered starter motor to start the engine.
In yet another aspect, the present disclosure is directed toward a control system for starting a plurality of engines including a first engine and a second engine, the system including a compressed air source in communication with the plurality of engines; an electric power source in communication with the plurality of engines; and a control module in communication with the plurality of engines, the compressed air source, and the electric power source, the control module configured to command the compressed air source to provide compressed air to an air-powered starter motor to start the plurality of engines when the compressed air source is in a first state and to command the electric power source to provide electric power to an electric-powered starter motor to start the plurality of engines when the compressed air source is in a second state.
In a still further aspect, the present disclosure is directed toward a method for starting multiple power modules, the method including the steps of evaluating a compressed air source to determine whether the compressed air source is in a first state or a second state; communicating a first start signal to an air starter system for starting a first power module when the compressed air source is in the first state; communicating a second start signal to an electric starter system for starting the first power module when the compressed air source is in the second state; communicating a third start signal to the air starter system for starting a second power module when the compressed air source is in the first state; and communicating a fourth start signal to the electric starter system for starting the second power module when the compressed air source is in the second state.
A locomotive may include multiple engines so that only the engines needed to match the power demand of the locomotive are running, as described in examples below. The remaining engines are switched off to conserve energy and reduce wear on the engines. This may factor into the designation of the engines as Engine A, B, C throughout the lifetime of the locomotive, e.g., as Engine A endures more use and wear than Engines B and C, the engine control module may change the designation of the engines such that Engine B becomes Engine A, Engine C becomes Engine B, and Engine A becomes Engine C. The switching on and off of only the engines needed to match the power demand generally indicates that the engines of the locomotive start and stop relatively frequently as compared to normal 100% operation of an engine associated with the locomotive.
The control strategy illustrated in
If the engine control module determines in step 102 that the power output requirement is above the first threshold power output, then the control strategy continues to step 110, shown in
If the engine control module determines that there is not sufficient air pressure to start both Engines A and B using an air start system, then the engine control module determines in step 118 whether there is sufficient compressed air pressure to start only Engine A. If the engine control module determines that there is sufficient compressed air pressure to start only Engine A, then Engine A is started in step 120 using an air start system and Engine B is started in step 122 using an electric start system. In an exemplary embodiment, Engines A and B are sequentially started. In another exemplary embodiment, Engines A and B are simultaneously started.
If the engine control module determines that there is not sufficient compressed air pressure to start only Engine A using an air start system, then the engine control module next determines in step 124 whether sufficient compressed air pressure exists to start only Engine B using an air start system. This may occur in a situation in which Engine B is a different capacity engine than Engine A that requires less compressed air to start than compared to Engine A. If the engine control module determines that there is sufficient compressed air pressure to start only Engine B, then Engine B is started in step 126 using an air start system and Engine A is started in step 128 using an electric start system. In an exemplary embodiment, Engines B and A are sequentially started. In another exemplary embodiment, Engines B and A are simultaneously started.
If the engine control module determines that there is not sufficient air pressure to start only Engine B using an air start system, then Engine A is started in step 130 using an electric start system and Engine B is started in step 132 using an electric start system after a sufficient time delay after Engine A is started. The time delay is provided to prevent overload of the electric current capacity of the electric power source.
If the engine control module determines in step 110 that the power output requirement is above the second threshold power output, then the control strategy continues to step 134, shown in
If the engine control module determines that there is not sufficient air pressure to start all of Engines A, B, and C using an air start system, then the engine control module determines in step 140 whether sufficient air pressure to start only Engines A and B exists in the on-board compressed air tank or other compressed air source by completing a pressure check of the compressed air tank. If the engine control module determines that there is sufficient air pressure to start only Engines A and B, then Engines A and B are started in step 142 using an air start system and Engine C is started in step 144 using an electric start system. There may be a delay between starting Engine A and starting Engine B if system limitations dictate a time delay such that sufficient air pressure remains for starting the second engine, as described above.
If the engine control module determines that there is not sufficient air pressure to start only Engines A and B using an air start system, then the engine control module next determines in step 146 whether there is sufficient compressed air pressure to start only Engine A. If the engine control module determines that there is sufficient compressed air pressure to start only Engine A, then Engine A is started in step 148 using an air start system, Engine B is started in step 150 using an electric start system, and Engine C is started in step 152 using an electric start system. There may be a delay between starting Engine B and Engine C if system limitations dictate a time delay such that sufficient electric power is available for starting the second engine and to prevent overloading the electric power source.
If the engine control module determines that there is not sufficient air pressure to start only Engine A using an air start system, then the engine control module determines in step 154 whether sufficient air pressure exists to start only Engine B using an air start system. If the engine control module determines that there is sufficient compressed air pressure to start only Engine B, then Engine B is started in step 156 using an air start system, Engine A is started in step 118 using an electric start system, and Engine C is started in step 160 using an electric start system. There may be a delay between starting Engine A and Engine C if system limitations dictate a time delay such that sufficient electric power is available for starting the second engine and to prevent overloading the electric power source.
If the engine control module determines that there is not sufficient compressed air pressure to start only Engine B using an air start system, then Engine A is started in step 162 using an electric start system, Engine B is started in step 164 using an electric start system after a sufficient time delay after Engine A is started, and Engine C is started in step 166 using an electric start system after a sufficient time delay after Engine B is started.
When either Engine A, B, or C is attempted to be started using an air start system either once or twice and cannot be cranked sufficiently, i.e., if the engine does not start within a preset time frame such as thirty seconds, then the engine control module defaults to starting the engine using the electric start system.
The control strategy illustrated in
If the engine control module determines in step 202 that the power output requirement is above the first threshold power output, then the control strategy continues to step 210, shown in
If the engine control module determines that there is not sufficient air pressure to start both Engines B and C using an air start system, then the engine control module determines in step 216 whether there is sufficient air pressure to start only Engine B. If the engine control module determines that there is sufficient air pressure to start only Engine B, then Engine B is started in step 218 using an air start system and Engine C is started in step 220 using an electric start system.
If the engine control module determines that there is not sufficient air pressure to start only Engine B using an air start system, then the engine control module determines in step 222 whether sufficient air pressure exists to start only Engine C using an air start system. If the engine control module determines that there is sufficient air pressure to start only Engine C, then Engine C is started in step 224 using an air start system and Engine B is started in step 226 using an electric start system. If Engine C cannot be cranked sufficiently, i.e., if Engine C does not start within a preset time frame such as thirty seconds and/or suffers two failed cranking attempts, then the engine control module defaults to starting Engine C using an electric start system.
If the engine control module determines that there is not sufficient air pressure to start only Engine C using an air start system, then Engine B is started in step 228 using an electric start system and Engine C is started in step 230 using an electric start system after a sufficient time delay after Engine B is started, as described above.
The disclosed control system and strategy for starting power systems may be applicable to provide control for starting a power system having a plurality of power modules. For example, a multi-engine generator set switcher locomotive has three power modules each of which have an engine associated therewith as a power source. Upon receiving a command from the locomotive indicating to the engine control module to start at least one engine, the control strategy determines whether to start the engine with an air or electric start. The control strategy starts only a single engine at a time, thereby avoiding overloading the airflow capacity of the compressed air source or the electric power capacity of the electric source. The control strategy also implements a command to start every engine with an air starter, if possible, to preserve the electric starter motor and the electric power capacity of the electric source.
As shown in
It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed system without departing from the scope of the disclosure. Other embodiments of the system will be apparent to those skilled in the art from consideration of the specification and practice of the system disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.