Engine-driven working machine

Abstract

An engine-driven working machine 1 is provided with: a diesel engine 10; a generator body 30 driven by the engine 10; an exhaust gas purification device 20 for purifying exhaust gas discharged from the engine 10; a VGT 13 for throttling intake air to the engine 10; and a reserve load 40 which can be connected between the generator body 30 and a load. The VGT 13 is throttled when removing deposition substances in the exhaust gas purification device 20, thereby increasing the temperature of exhaust gas from the engine 10, and the reserve load 40 is connected to the generator body 30 when throttling intake air in order to remove deposition substances in the exhaust gas purification device 20, thereby increasing the amount of intake air to the engine 10.

Claims

1. An engine-driven working machine, comprising: a diesel engine; a generator driven by the diesel engine; an exhaust purifier that purifies an exhaust gas emitted from the diesel engine; at least one intake air reducer that reduces an amount of intake air taken into the diesel engine; a preload that is able to be connected between the generator and a load; and a turbocharger for supercharging the intake air of the diesel engine, wherein: the engine-driven working machine reduces the amount of the intake air by means of the intake air reducer to raise a temperature of the exhaust gas emitted from the diesel engine so that a deposit in the exhaust purifier is removed, and the engine-driven working machine connects the preload to the generator so that a load is applied forcibly to increase a supercharging pressure of the turbocharger and increase the amount of the intake air taken into the diesel engine, prior to reducing the amount of the intake air by means of the intake air reducer to remove the deposit in the exhaust purifier, thereby reducing a drop of the supercharging pressure when then intake air reducer reduces the amount of the intake air to remove the deposit in the exhaust purifier.

2. The engine-driven working machine of claim 1, wherein the exhaust purifier is a urea selective catalyst reduction apparatus.

3. The engine-driven working machine of claim 1, wherein the exhaust purifier is at least one of a urea selective catalyst reduction apparatus or a diesel particulate filtering apparatus.

4. The engine-driven working machine of claim 1, wherein: the intake air reducer is a movable vane of the turbocharger.

5. The engine-driven working machine of claim 1, wherein a capacity of the preload is set such that, when the amount of the intake air is reduced by the intake air reducer to remove the deposit in the exhaust purifier, the supercharging pressure during a no-load operation of the diesel engine becomes 90% or more of the supercharging pressure during the no-load operation before reducing the amount of the intake air.

6. The engine-driven working machine of claim 1, wherein: the diesel engine is provided with a throttle valve that adjusts the amount of the intake air taken into the diesel engine, and the intake air reducer is the throttle valve.

7. The engine-driven working machine of claim 1, wherein the preload is an electric heater.

8. The engine-driven working machine of claim 7, wherein the preload is arranged in an exhaust passage of the diesel engine.

9. The engine-driven working machine of claim 1, wherein the deposit in the exhaust purifier is removed every predetermined time.

10. The engine-driven working machine of claim 1, wherein a capacity of the preload is set such that, when the amount of the intake air is reduced by the intake air reducer to remove the deposit in the exhaust purifier, a load factor of the engine during a no-load operation of the diesel engine becomes 30% or more.

11. The engine-driven working machine of claim 1, further comprising: an engine controller that controls an operation of the diesel engine; and a preload controller that controls an operation of the preload, wherein: the engine controller transmits a purge request signal for requesting a purge process of removing the deposit in the exhaust purifier to the preload controller, and the preload controller turns the preload on when the purge request signal is received.

12. The engine-driven working machine of claim 11, further comprising: a controller that transmits a purge prohibition signal for prohibiting the purge process and a purge prohibition cancellation signal for canceling the purge prohibition signal to the engine controller, wherein the controller transmits the purge prohibition signal to the engine controller in a normal operation and transmits the purge prohibition cancellation signal to the engine controller after a predetermined time has passed since the receipt of the purge request signal.

13. The engine-driven working machine of claim 12, wherein the controller transmits the purge prohibition cancellation signal to the engine controller at least one of: when the supercharging pressure is: greater than a threshold for a predetermined time, when an engine load factor is greater than a threshold for a predetermined time, or after a predetermined time has passed since the receipt of the purge request signal.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) FIG. 1 is a schematic side view of an engine-driven power generator according to an embodiment.

(2) FIG. 2 is a connection diagram of major components of an engine-driven power generator according to an embodiment.

(3) FIG. 3 is a timing chart of an engine-driven power generator according to an embodiment.

(4) FIG. 4 is a flowchart of an SCR board constituting an engine-driven power generator according to an embodiment.

(5) FIG. 5 is a flowchart of a control board constituting an engine-driven power generator according to an embodiment.

(6) FIG. 6 is a schematic cross-sectional view of a major part of a turbocharger constituting an engine accessory in an engine-driven power generator according to an embodiment.

(7) FIG. 7 is a schematic cross-sectional view of a combustion chamber and an intake/exhaust portion that constitute an engine in an engine-driven power generator according to an embodiment.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

(8) A urea SCR apparatus for purifying NO.sub.x may be mounted as an exhaust purification apparatus on an engine-driven power generator using a diesel engine as a driver for the power generator. As described above, a purge process needs to be performed on the urea SCR apparatus periodically, for example, every tens of hours. The purge process takes about ten minutes at the maximum. To maintain the performance of the urea SCR apparatus, there has been no other choice but to accept deterioration in the speed governing performance of the engine when a load is inputted in the course of the purge process.

(9) However, if the engine-driven power generator is used in an unattended situation, for example, the deterioration in the speed governing performance cannot be ignored because the response to a continuous load such as a pump and a compressor may be delayed, or a load (device) in use may be stopped.

(10) The inventors of the present application have found that increasing an intake pressure, e.g., a boost pressure, in advance before the purge process by an amount that compensates for the pressure drop can reduce the deterioration in the speed governing performance.

(11) Note that in an engine speed governing performance test, settling time needs to be eight seconds or less at the start of the engine when the load is inputted, and speed variation of the engine at the time of inputting the load needs to be within 10%.

Exemplary Embodiment

(12) An embodiment of the present disclosure will be described in detail below with reference to the drawings. The following description of the embodiments is merely an example in nature, and is not intended to limit the scope, applications, or use of the present disclosure.

(13) An embodiment of the present disclosure will be described below with reference to the accompanying drawings.

(14) FIG. 1 schematically illustrates a configuration of an engine-driven power generator which is an example of an engine-driven working machine according to an embodiment as viewed from the side. A front bonnet is not shown for the sake of convenience. As shown in FIG. 1, an engine-driven power generator 1 has a housing 4 including a frame 2 serving as a base, and a bonnet 3 covering the frame 2.

(15) The frame 2 carries thereon a water-cooled diesel engine (will be hereinafter simply referred to as an “engine”) 10, an exhaust purification apparatus 20 as an exhaust purifier, a generator (power generator) 30 which is a working body to be driven by the engine 10, a preload 40 which is able to be connected between the generator 30 and an electrically connected load (not shown), and a control section 50 which controls the engine 10 and the preload 40. Here, a resistor, e.g., an electric heater or a lamp, can be used as the preload 40. The electric heater or the lamp is stably operable as a load, and is easily available.

(16) A radiator 11 that exchanges heat with a coolant of the engine 10 is provided on the side of the engine 10. A cooling fan 12 that generates cooling air for cooling the radiator 11 is provided on a side surface of the engine 10 facing the radiator 11.

(17) The engine 10 may be provided with, for example, a throttle valve (not shown) which is arranged upstream of an intake manifold and can change the amount of intake air taken into cylinders. The throttle valve is an example of an intake air reducer.

(18) The engine 10 is provided with a turbocharger 13 arranged downstream of an exhaust manifold to supercharge the intake air by means of an exhaust pressure. In a preferred embodiment, the turbocharger 13 is a variable geometry turbocharger (VGT) having movable vanes. The movable vanes are an example of the intake air reducer. The exhaust purification apparatus 20 is connected to a downstream portion of an exhaust pipe 14 which emits an exhaust gas that has passed through the turbocharger 13.

(19) The exhaust purification apparatus 20 is, for example, a urea SCR apparatus connected to the downstream portion of the exhaust pipe 14 to reduce NOR. A urea water tank 23 containing urea water to be added as ammonia to the urea SCR apparatus is disposed on the frame 2 adjacent to the urea SCR apparatus.

(20) The exhaust purification apparatus 20 may be a DPF apparatus that collects particulate materials (PM), and may include both of the urea SCR apparatus and the DPF apparatus. Further, the exhaust purification apparatus 20 has an exhaust gas outlet 15.

(21) The preload 40 is arranged across the radiator 11 from the engine 10 on the frame 2. That is, the preload 40 is disposed in the middle of an exhaust passage, and can be cooled without using any other means. In addition, the preload 40 serves as a shield against engine sound and the air emitted from the radiator 11, thereby reducing the noise of the engine-driven power generator 1.

(22) The control section 50 includes, for example, an engine control module (ECM) 51, an SCR board 52, a control board 53, and a contactor 54. The ECM 51 is an example of an engine controller including the engine 10 and its accessories. The SCR board 52 is an example of a preload controller that controls the contactor 54 connecting or disconnecting the preload 40 and the generator 30. The control board 53 transmits, to the ECM 51, a purge prohibition signal and a cancellation signal for the purge prohibition signal. The control board 53 is an example of a controller. The ECM 51, the SCR board 52, and the control board 53 are respectively provided with a microprocessor, a memory device and an input/output device, and are connected to each other by electrical wiring to be able to communicate with each other. A communication protocol in this case may be, for example, a controller area network (CAN) protocol.

(23) FIG. 2 is a connection diagram of the engine-driven power generator 1 according to the present embodiment. As shown in FIG. 2, the ECM 51, the SCR board 52, and the control board 53 are connected to each other by a twisted pair wire.

(24) The ECM 51 is electrically connected to the engine 10. Specifically, the ECM 51 is electrically connected to a plurality of sensors provided for the engine 10, such as an intake pressure sensor, a supercharging pressure (will be hereinafter referred to as a “boost pressure”) sensor, and a torque sensor.

(25) The engine 10 is connected to the generator 30, which is connected to the contactor 54 and a main load (a load used by a user) 60.

(26) The SCR board 52 is connected to the contactor 54, which is connected between the generator 30 and the preload 40 to be able to connect and disconnect the generator 30 and the preload 40.

(27) (Purge Process for Exhaust Purification Apparatus)

(28) FIG. 3 is a timing chart of a purge process performed on the urea SCR apparatus as the exhaust purification apparatus 20. Among a plurality of types of purge processes, the purge process performed in this example is a process of removing a white product (cyanuric acid) deposited in the urea SCR apparatus through sublimation at high temperature.

(29) The timing of performing the purge process will be described below with reference to FIGS. 2 and 3. In this example, the engine-driven power generator 1 is assumed to be in a normal operation state where no purge process is performed.

(30) (1) When the engine 10 is normally operating, the control board 53 transmits a purge prohibition signal to the ECM 51 at a predetermined cycle.

(31) (2) The ECM 51 transmits a purge request signal to the control board 53 and the SCR board 52, for example, every accumulated predetermined operation time, such as every thirty hours. Receiving the purge request signal, the SCR board 52 allows the contactor 54 to connect the preload 40 to the generator 30, thereby turning the preload 40 on.

(32) (3) On the other hand, when the boost pressure or engine load factor of the engine 1 is greater than a predetermined threshold for a predetermined time, the control board 53 having received the purge request signal transmits a cancellation signal for the purge prohibition signal (i.e., an OFF signal for the purge prohibition signal) to the ECM 51. At the same time, the ECM 51 instructs the engine 10 to reduce the amount of intake air, and raises the temperature of the exhaust gas to start the purge process. The reason why the threshold of the engine load factor is also used as the target of the determination in addition to that of the boost pressure is to take a pressure drop that may occur in the case where the engine-driven power generator 1 is used in the highlands into consideration.

(33) To reduce the amount of the intake air taken into the engine 10, intervals of the movable vanes of the turbocharger 13 may be adjusted (increased) or the throttle valve may be slightly closed. Alternatively, both may be performed at the same time.

(34) Here, it will be shown a schematic configuration of an exhaust side (FIG. 6) of the turbocharger 13 which is the VGT and the throttle valve (FIG. 7).

(35) As shown in FIG. 6, the turbocharger 13 includes a turbine wheel 13a that receives the exhaust gas, and a plurality of movable vanes 13b disposed around the turbine wheel 13a to adjust the flow rate of the exhaust gas through adjustment of the intervals therebetween. When the intervals between the movable vanes 13b are slightly increased, the rotation of the turbine wheel 13a is slowed to reduce the amount of the intake air, when the exhaust amount is the same.

(36) As shown in FIG. 7, the engine 10 includes a piston 10a, an intake valve 10c and an exhaust valve 10d which constitute a combustion chamber 10b together with a top surface of the piston 10a, an intake pipe 10e whose downstream end is opened and closed by the intake valve 10c, and an exhaust pipe 14 whose upstream end is opened and closed by the exhaust valve 10d. An injection nozzle 10 g for injecting fuel is provided in an upper portion of the combustion chamber 10b between the intake valve 10c and the exhaust valve 10d. A throttle valve 10h that adjusts the flow rate of the intake air is provided in the intake pipe 10e upstream of the intake valve 10c.

(37) (4) As shown in the graph of the boost pressure in the bottom part of FIG. 3, the boost pressure drops at stage (3) in a conventional case where no preload is inputted. If the main load 60 were inputted at this stage, the speed governing performance of the engine 10 would not possibly be maintained. However, in the present embodiment, the preload 40 is previously inputted at stage (2) to raise the boost pressure to a level higher than a predetermined threshold. Thus, even if the boost pressure drops when the purge process is started, the boost pressure can be substantially maintained to that in the normal operation at stage (4). This indicates that the speed governing performance of the engine 10 is improved.

(38) (5) The purge process of the present invention generally ends in ten minutes or less. Thus, when the purge process ends, the ECM 51 transmits a cancellation signal for the purge request signal (an OFF signal for the purge request signal) to the control board 53 and the SCR board 52. The control board 53 transmits the purge prohibition signal to the ECM 51. The ECM 51 that has received the purge prohibition signal instructs the engine 10 to return the amount of the intake air to that in the normal operation, and ends the purge process. Upon receiving the OFF signal of the purge request signal, the SCR board 52 allows the contactor 54 to disconnect the preload 40 and the generator 30, thereby turning the preload 40 off.

(39) (6) After the purge process ends, the control board 53 transmits the purge prohibition signal to the ECM 51 until the next purge request signal is received.

(40) An example of the details of a purge process control flow in the ECM 51, the SCR board 52, and the control board 53 which communicate with each other through the CAN protocol will be described below with reference to the accompanying drawings.

(41) FIG. 4 shows an outline of a purge process control flow in the SCR board 52, and FIG. 5 an outline of a purge process control flow in the control board 53.

(42) As shown in FIG. 4, in the SCR board 52, whether the speed of the engine 10 is low or high is determined in step ST10. In the present embodiment, the engine 10 changes the operation mode depending on whether the engine speed is low or high. A low-speed rotation mode is, for example, an operation mode for first several minutes during warming-up after the start, and in this case, the engine 10 rotates at about 1000 rpm, for example. A high-speed rotation mode is an operation mode for the power generator. For example, when an output frequency of the power generator is 60 Hz, the engine 10 rotates at about 1800 rpm, and the switching between the low-speed rotation mode and the high-speed rotation mode is manually performed.

(43) If the determination in step ST10 is true, that is, in the low-speed rotation mode, the SCR board 52 allows the contactor 54 to disconnect the preload 40 and the generator 30 to turn the preload 40 off in the subsequent step ST11. Thereafter, the flow returns to step S10.

(44) If the determination in step ST10 is false, i.e., in the high-speed rotation mode, it is determined in the subsequent step ST12 whether the purge request signal has been received from the ECM 51 or a signal indicating that the purge process is being performed has been received from the ECM 51. If the determination in step ST12 is true, the SCR board 52 allows the contactor 54 to connect the preload 40 and the generator 30 to turn the preload 40 on in the subsequent step ST13. Thereafter, the flow returns to step S10.

(45) If the determination in step ST12 is false, the SCR board 52 allows the contactor 54 to disconnect the preload 40 and the generator 30 to turn the preload 40 off in the subsequent step ST14. Thereafter, the flow returns to step S10.

(46) Then, as shown in FIG. 5, in the control board 53, it is determined in step ST20 whether the purge request signal has been received from the ECM 51 or the signal indicating that the purge process is being performed has been received from the ECM 51. If the determination in step ST20 is true, the flow proceeds to the subsequent step ST21. If the determination in step ST20 is false, the flow proceeds to the subsequent step ST22, and the control board 53 transmits the purge prohibition signal to the ECM 51. Thereafter, the flow returns to step ST20.

(47) In step ST21, it is determined whether the boost pressure of the engine 10 is greater than a predetermined threshold (a value converted from 111% which is a reference boost pressure comparison value to be described later) for a predetermined time, the engine load factor is greater than about 34% which is a predetermined threshold for a predetermined time, or a predetermined time has passed since the receipt of the purge request signal. The predetermined time can be counted in the control board 53, for example, as a time lapse of one to five minutes. It is assumed that the determination of the lapse of time after the receipt of the purge request signal is made true in the low-speed rotation mode in FIG. 4, i.e., during the warming-up.

(48) If the determination in step ST21 is true, the control board 53 transmits the cancellation signal for the purge prohibition signal to the ECM 51 in the subsequent step ST23. If the determination in step ST21 is false, the flow proceeds to the subsequent step ST22, and the control board 53 transmits the purge prohibition signal to the ECM 51.

(49) It has been confirmed that if an electric heater whose capacity is set to about 8.6 kW to 12 kW is used as the preload 40, the speed governing performance of the engine 10 can be maintained when the boost pressure of the turbocharger 13 during a no-load operation with the amount of the intake air reduced is more than about 90% of the boost pressure during the normal operation, i.e., when no purge process is performed. This is based on the premise that the speed governing performance of the engine 10 can be maintained as long as the boost pressure can be kept approximately equal to that in a standby state with no load even during the purge process.

(50) It has also been confirmed that the speed governing performance of the engine 10 can be maintained when the load factor of the engine 10 during the no-load operation with the amount of the intake air reduced is more than about 30%. In this case, the present invention is also applicable to an engine with no turbocharger 13.

EXAMPLES

(51) A speed governing performance test was performed using the engine-driven power generator 1 of the present embodiment as an example. In this test, a load value that could be inputted during the purge process was reduced to about 55% of a load value that could be inputted during the normal operation in which no purge process was performed. Then, it has been confirmed that in an example in which the preload 40 having the capacity described above was inputted before the purge process, the load value that could be inputted during the purge process was recovered to about 85% of the load value that could be inputted during the normal operation.

(52) A reference boost pressure comparison value described below represents a value (%) calculated with reference to the boost pressure during the normal operation in which neither the load nor the preload is inputted and no purge process is performed.

(53) It has been confirmed that the reference boost pressure comparison value decreased to 66% when neither the load (main load) nor the preload was inputted during the purge process.

(54) In selecting a resistance value required for the electric heater used as the preload 40, i.e., a required preload capacity, to maintain the speed governing performance, a plurality of capacities were set, and a preload set during the purge process was sequentially inputted to measure the engine load factor and the reference boost pressure comparison value with respect to the set values. In this test, no load (main load) was inputted.

(55) As a result, it has been confirmed that the reference boost pressure comparison value was as low as about 70% when the capacity of the preload 40 was 8.4 kW or less, and was recovered up to 92% when the capacity of the preload 40 was 8.6 kW.

(56) It has also been confirmed that the reference boost pressure comparison value had little variation when the capacity was 8.6 kW or more.

(57) From the above, the reference boost pressure comparison value relative to the capacity of the preload 40 may be satisfactory if it is 90% or more, but in the present embodiment, the capacity of the preload 40 is set to 12 kW to make some allowance.

(58) As can be seen in the foregoing, when the boost pressure is 90% or more with respect to that in the normal operation, sufficient speed governing performance can be achieved even during the purge process.

(59) On the other hand, the engine load factor was 27% or less when the capacity was 8.4 kW or less, and exceeded 30% when the capacity was 8.6 kW or more. It has been confirmed that the load factor had relatively small variation when the capacity was between 8.6 kW and 14 kW, and in this case, a value of 30% or more can be set as a threshold.

(60) In step ST21 shown in the flowchart of FIG. 5, the reference boost pressure comparison value, which was 111%, for converting the threshold of the boost pressure of the engine 10, and the threshold of the engine load factor, which was about 34%, were values obtained when a load of 12 kW was inputted.

(61) Further, regarding the boost pressure when the preload 40 having the capacity set to 12 kW was inputted before the purge process, it has been confirmed that the reference boost pressure comparison value did not fall below 97% during the purge process because the preload 40 was inputted before the input of the load (main load). It has also been confirmed that the boost pressure was effectively raised when the load of 5 kW or less was inputted and a load of 35 kW or more was inputted.

(62) [Advantages]

(63) According to this embodiment, the electric heater, which is the preload 40, is connected to the generator 30 (immediately) before periodically, or automatically, performing the purge process of removing the white product from the urea SCR apparatus. When the preload 40 is inputted to the generator 30 in this way, the boost pressure of the intake air to the engine 10 increases, and the torque of the engine 10 increases, thereby improving the speed governing performance. Thus, the main load 60, which is higher than a main load inputted with no input of the preload 40 when performing the purge process, can be inputted. Thus, there is little need to limit the capacity of the main load (device) 60 which can be inputted during the purge process.

(64) For example, from the viewpoint of maintaining the speed governing performance, the capacity of the main load during a conventional purge process with no preload input is only about 55% of the capacity of the main load during the normal operation. On the other hand, during the purge process according to the present embodiment in which the preload 40 is inputted, the capacity of the main load 60 is increased to about 85% of that during the normal operation.

(65) Further, regarding an intermittent and large load such as a pump jack used in the site of oil field excavation, for example, response to the intermittent load is improved even during the purge process, and thus, a situation in which the pump jack stops can be avoided.

(66) Moreover, since the exhaust temperature is raised by the amount corresponding to the preload 40 inputted, the purge process on the exhaust purification apparatus 20 is more normally completed.

(67) The engine-driven working machine of the present embodiment is not limited to the engine-driven power generator, and can be applied to an engine-driven welding machine using a diesel engine as a driver for a power generator.

(68) (Variation of Exhaust Purification Apparatus)

(69) In the above embodiment, the urea SCR apparatus has been used as the exhaust purification apparatus 20, but a DPF apparatus may be used in place of the urea SCR apparatus as a variation of the exhaust purification apparatus 20. In this case, the exhaust purification apparatus 20 collects particulate materials (PM), thereby purifying the exhaust gas emitted outside. However, when the diesel engine is continuously operated for a long time, PM is attached to the DPF apparatus to block the flow of the exhaust gas, resulting in a decrease in the output of the diesel engine. Thus, a heat regeneration process is performed to remove PM attached to the DPF apparatus.

(70) Even when the DPF apparatus is used as the exhaust purification apparatus 20, the exhaust temperature is raised to 350° C. or more during the purge process (regeneration process for the DPF apparatus) according to the present embodiment. This can remove PM deposited on the filter.

(71) The engine-driven working machine of the present disclosure can reduce deterioration of speed governing performance even in a purge process (deposit removal process) performed on an exhaust purifying apparatus, and is useful, for example, as an engine-driven working machine that can be operated in an unattended situation.