Note: Descriptions are shown in the official language in which they were submitted.
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Title: A MANAGEMENT SYSTEM AND METHOD FOR REGULATING THE
ON-DEMAND ELECTROLYTIC PRODUCTION OF HYDROGEN AND OXYGEN
GAS FOR INJECTION INTO A COMBUSTION ENGINE
FIELD
[0001]
The embodiments described herein relate to a system and method
for managing an on-demand electrolytic reactor for supplying hydrogen and
oxygen gas to an internal combustion engine. In particular, the embodiments
relate to a management system and method that can simultaneously reduce
emissions and improve the performance of an internal combustion engine by:
determining the reactor performance level or calculating the amount of gas
being
generated by the on-demand electrolytic reactor; monitoring the engine
performance level, determining whether the engine performance level would
change, i.e. decrease or increase, or remain the same to forecast a future
engine
demand level; adjusting the reactor performance level to improve the engine
performance ahead of the forecast future engine demand level materializing to
minimize parasitic loss associated with reactors operating continuously, i.e.
reactors that are not capable of adjusting their performance level or the
level of
produced gas according to the real time engine performance level; and,
thereby,
improving the engine performance and reducing emissions.
INTRODUCTION
[0002]
It has been shown in the art that addition of hydrogen and/or
oxygen to the pre-combustion mixture improves the combustion efficiency of
internal combustion engines. The improved combustion efficiency may result in
lowering emissions and/or improving fuel economy. To achieve this result, an
electrolytic reactor is responsible to generate hydrogen and oxygen using
water.
In order to operate, the reactor requires a power source. In case of an add-on
reactor that is installed within a vehicle, the power source is the vehicle's
engine.
In absence of a proper management and control system, the reactor operates
continuously. The uninterrupted supply of hydrogen and oxygen to the engine
may not always result in reduced emissions or improved fuel economy. External
conditions, such as level of oxygen in the surrounding air, temperature,
altitude,
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humidity, road surface and its grade, etc., can make the operation of the
reactor
unnecessary.
[0003] Accordingly, if the reactor functions ceaselessly without
control to
supply gas, the engine performance may not be improved. The reactor is drawing
power from the engine to keep generating gas. As a result, the power produced
by the engine is not consumed entirely for the propulsion and vehicle's
internal
demands, such as recharging the vehicle's battery or illuminating the road
using
its lighting system. It is well known that addition of a reactor introduces an
external demand or load on the engine. If the reactor works continuously
without
control, the power drawn from the engine for the reactor's operation may
become
a parasitic loss to the engine. As a result, emissions may be reduced without
improving the fuel efficiency. There are numerous prior arts addressing
addition
of an electrolytic reactor to improve emissions, as discussed below. However,
none of the references discusses a management and control system that can
reduce parasitic engine loss associated with these reactors to thereby improve
the engine performance and fuel economy and reduce emissions,
simultaneously.
[0004] De Souza et al. in US6332434 disclose a system and process
for
generating hydrogen for use in an internal combustion engine. De Souza teaches
monitoring specific engine parameters and adjusting the rate of reaction by
regulating the amount of provided electrical energy. In De Souza, the
operation
of the hydrogen generating system may be monitored through sensors and
corrected when operating outside normal conditions. However, the normal
conditions, the control and the monitoring in De Souza are for safety features
and
not for improving the performance of the engine. Further, the system in De
Souza
does not utilize sensors to calculate the amount of the gas being generated.
The
amount of the gas produced by the reactor correlates with the power consumed
by the reactor to generate the gas. As a result, the system in De Souza cannot
monitor the engine's energy loss associated with operation of the reactor and
cannot minimize the loss. In other words, De Souza may be able to improve fuel
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efficiency but it will never minimize the impact of the reactor because the
system
taught by De Souza does not minimize the reactor's power consumption.
[0005] Fong et al.in US20110303194 disclose systems and methods for
improving combustion and engine performance through controlled oxyhydrogen
injection. This prior art discloses reading combustion parameters from the
engine
control module and modifying hydrogen production by controlling the supplied
electrical current. However, Fong et al. do not appear to teach determining
the
amount of gas generated by the reactor.
[0006] Dee et al. in US20110094459 disclose systems and methods for
managing the operation of a modified engine with hydrogen and oxygen
injection.
Dee teaches dynamically generating hydrogen and oxygen based on engine
operating characteristics by managing the supplied electrical current. Similar
to
other prior arts cited above, the system as taught by Dee et al does not
determine the amount of gas generated by the reactor so as to adjust the
reactor
operating condition to reduce parasitic engine's energy loss and improve the
engine's efficiency.
[0007] As it is evident from the above discussion of prior arts,
there is
currently a need for a managing system that can control on-demand generation
of hydrogen and oxygen by an electrolytic reactor to reduce emissions and
improve fuel economy and engine performance simultaneously. The inventors'
solution is to measure the reactor performance level by monitoring a plurality
of
reactor parameters through a plurality of sensors, thereby calculating the
amount
of gas being generated, determining the real time engine performance level by
monitoring a plurality of engine parameters, determining a change in the
engine
performance level to forecast, ahead of time, a future engine demand level,
and
adjusting the reactor performance level to produce gas in an amount that can
improve the engine performance prior to the forecast future engine demand
level
taking place. Monitoring the engine performance in real time can be used to
predict the future engine demand level; this, in combination with knowing and
controlling the reactor's gas production rate, will provide the means to
produce
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and deliver the gas in real time in an amount that will improve the engine
performance while the engine is operating either at the determined engine
performance level or at the forecast future engine demand level. In other
words,
the reactor does not show a reactionary response to what has already happened.
The reactor is always one step ahead and ready to supply the engine with the
amount of gas required at any instant.
SUMMARY
[0008] The embodiments described herein provide in one aspect a
system
for managing an on-demand electrolytic reactor for supplying hydrogen and
oxygen gas to an internal combustion engine. The system minimizes amount of
power drawn from the engine for the reactor to operate and thereby the system
minimizes parasitic energy loss generally associated with perpetual reactors.
The
engine measures and stores a plurality of engine parameters. The system
comprises an electronic control unit ("ECU") connected to a plurality of
sensors
coupled to the reactor that are configured to measure a plurality of reactor
parameters and a reactor control board ("RCB") coupled to the reactor. The
electronic control unit ("ECU") is configured to monitor the plurality of
reactor
parameters and the plurality of engine parameters; determine a reactor
performance level based on at least one of the plurality of reactor
parameters;
determine an engine performance level based on at least one of the plurality
of
engine parameters; determine a change in the engine performance level to
forecast a future engine demand level; and determine an ideal reactor
performance level corresponding to the determined engine performance level,
or,
if a change in the engine performance level was determined, to the forecast
future engine demand level. The reactor control board ("ROB") is configured to
regulate the reactor in response to the ideal reactor performance level
determined by the electronic control unit ("ECU") by modifying at least one of
electrical current supplied to the reactor, electrical voltage supplied to the
reactor,
and temperature of the reactor.
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[0009] The embodiments described herein provide in another aspect a
similar system in which the ECU is further configured to recalibrate the
plurality of
engine parameters stored in the engine based on at least one of the plurality
of
reactor parameters.
[0010] In another aspect, the ECU of the same system is further
configured to detect an occurrence of at least one of the plurality of reactor
parameters existing outside a normal operating range and the ECU is further
configured to regulate the reactor in response to the occurrence.
[0011] In yet another aspect, the plurality of reactor parameters
monitored
by the ECU comprises at least one of the following: water tank level,
electrolyte
level, supplied electrical voltage, supplied electrical current, water tank
temperature, reactor temperature, reactor leakage, water pump, gas flow,
relative
humidity, conductivity of electrolyte, resistance of electrolyte, and
concentration
of electrolyte.
[0012] In the other aspect, the plurality of engine parameters comprises at
least one of: odometer, engine speed, fuel consumption, fuel rate, mass air
pressure, mass air flow, mileage, distance, fuel rate, exhaust temperature,
NOx
levels, CO2 levels, 02 levels, engine instantaneous fuel economy, engine
average fuel economy, engine inlet air mass flow rate, engine demand percent
torque, engine percent load at current speed, transmission actual gear ratio,
transmission current gear, engine cylinder combustion status, engine cylinder
knock level, and after treatment intake NO level preliminary FMI, drivetrain,
vehicle speed and GPS location.
[0013] In one more aspect, the system further comprises a storage
module
coupled to the electronic control unit, the storage module configured to store
the
plurality of reactor parameters, the plurality of engine parameters, the
reactor
performance level, and the engine performance level.
[0014] In yet one more aspect, the system further comprises a
display
module coupled to the electronic control unit, the display module configured
to
visually display a performance indicator based on at least one of: at least
one of
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the plurality of reactor parameters, at least one of the plurality of engine
parameters, the reactor performance level, and the engine performance level.
[0015] In another aspect, the system further comprises a
communication
module coupled to the ECU. The communication module is configured to transmit
a first plurality of data to a remote server and receive a second plurality of
data
from the remote server. The first plurality of data comprises the plurality of
reactor parameters, the plurality of engine parameters, the reactor
performance
level, and the engine performance level. The second plurality of data
comprises
the ideal reactor performance level and instructions to the reactor control
board
for achieving the ideal reactor performance level. The second plurality of
data is
generated based on at least one of historical trends of the transmitted first
plurality of data and comparison to other first plurality of data transmitted
from
other ECUs in communication with the remote server.
[0016] In yet another aspect, if the engine is not equipped with an
engine
control module and the electronic control unit cannot monitor the plurality of
engine parameters, the electronic control unit communicates with the remote
server to find similar engine conditions to determine the ideal reactor
performance level.
[0017] In yet another aspect, if the engine is equipped with an
engine
control module, but the electronic control unit is unable to establish a
connection
with the engine control module, the electronic control unit can communicate
with
the remote server to find similar engine conditions to determine the ideal
reactor
performance level.
[0018] In yet another aspect, the system determines the ideal
reactor
performance level further based on optimizing at least one of engine
performance indicators according to their priorities. The engine performance
indicators comprise the following: fuel efficiency, emissions, engine torque,
and
engine horsepower.
[0019] The embodiments described herein provide in another aspect a
method for managing an on-demand electrolytic reactor for supplying hydrogen
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and oxygen gas to an internal combustion engine. The method minimizes
amount of power drawn from the engine for the reactor to operate. The method
minimizes parasitic energy loss generally associated with perpetual reactors.
The
reactor and engine are in communication with an electronic control unit. The
engine measures and stores a plurality of engine parameters. The method
comprises providing a plurality of sensors coupled to the reactor that are
configured to measure a plurality of reactor parameters, monitoring the
plurality
of reactor parameters, monitoring the plurality of engine parameters,
determining
a reactor performance level based on at least one of the plurality of reactor
parameters, determining an engine performance level based at least on one of
the plurality of engine parameters, determining a change in the engine
performance level to forecast a future engine demand level, determining an
ideal
reactor performance level corresponding to the determined engine performance
level, or, if a change in the engine performance level was determined, to the
forecast future engine demand level, and regulating the reactor in response to
the determined ideal reactor performance level by modifying at least one of
electrical current supplied to the reactor, electrical voltage supplied to the
reactor,
and temperature of the reactor.
[0020] In yet another aspect, the method further comprises
recalibrating
the plurality of engine parameters based on at least one of the plurality of
reactor
parameters.
[0021] In another aspect, the method further comprises detecting an
occurrence of at least one of the plurality of reactor parameters existing
outside a
normal operating range and regulating the reactor in response to the
occurrence.
[0022] In one more aspect, the plurality of reactor parameters comprises
at least one of water tank level, electrolyte level, supplied electrical
voltage,
supplied electrical current, water tank temperature, reactor temperature,
reactor
leakage, water pump, gas flow, relative humidity, conductivity of electrolyte,
resistivity of electrolyte, and concentration of electrolyte.
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[0023] In another aspect, the plurality of engine parameters
comprises at
least one of odometer, engine speed, fuel consumption, fuel rate, mass air
pressure, mass air flow, mileage, distance, fuel rate, exhaust temperature,
NOx
levels, CO2 levels, 02 levels, engine instantaneous fuel economy, engine
average fuel economy, engine inlet air mass flow rate, engine demand percent
torque, engine percent load at current speed, transmission actual gear ratio,
transmission current gear, engine cylinder combustion status, engine cylinder
knock level, and after treatment intake NO level preliminary FMI, drivetrain,
vehicle speed, and GPS location.
[0024] In yet another aspect, the method further comprises storing the
plurality of reactor parameters, the plurality of engine parameters, the
reactor
performance level, and the engine performance level.
[0025] In one more aspect, the method further comprises visually
displaying at least a performance indicator based on at least one of at least
one
of the plurality of reactor parameters, at least one of the plurality of
engine
parameters, the reactor performance level, and the engine performance level.
[0026] In another aspect, the method further comprises transmitting
a first
plurality of data to a remote server and receiving a second plurality of data
from
the remote server. The first plurality of data comprises the plurality of
reactor
parameters, the plurality of engine parameters, the reactor performance level,
and the engine performance level. The second plurality of data comprises the
ideal reactor performance level and instructions to the electronic control
unit for
achieving the ideal reactor performance level. The second plurality of data is
generated based on at least one of historical trends of the transmitted first
plurality of data and comparison to other first plurality of data transmitted
from
other engines to the remote server.
[0027] In yet another aspect, the ideal reactor performance level is
determined further based on optimizing at least one of engine performance
indicators, wherein the engine performance indicators comprise fuel
efficiency,
emissions, engine torque, and engine horsepower. The method further
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comprises prioritizing each of the engine performance indicators, determining
the
ideal reactor performance level required to optimize each of the engine
performance indicators ranked from highest to lowest and optimizing the
reactor
performance to achieve an improved engine performance based on aggregate of
the determined idea reactor performance levels.
[0028] Further aspects and advantages of the embodiments described
herein will appear from the following description taken together with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] For a better understanding of the embodiments described herein
and to show more clearly how they may be carried into effect, reference will
now
be made, by way of example only, to the accompanying drawings which show at
least one exemplary embodiment, and in which:
[0030] FIG. 1 is a block diagram of interactions between various
components, such as engine, electronic control module ("ECM"), electronic
control unit ("ECU"), reactor and reactor control board ("RCB") of the system
of
managing the electrolytic reaction for generating hydrogen gas to be injected
to
an internal combustion engine;
[0031] FIG. 2 is a block diagram of the system which further
comprises a
storage module coupled to the ECU to store reactor parameters, engine
parameters, reactor performance level, and engine performance level;
[0032] FIG. 3 is a block diagram of the system which further
comprises a
display module coupled to the ECU to visually display a performance indicator;
[0033] FIG. 4 is a block diagram of the system which further
comprises a
remote server in communication with the ECU to receive data from the ECU and
send data to the ECU;
[0034] FIG. 5 is a block diagram of the system which further
comprises a
storage module, display module, and remote server, all in communication with
the ECU;
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[0035] FIG. 6 is a flowchart of the steps performed by the system in
managing the electrolytic reaction for generating hydrogen gas to be injected
to
an internal combustion engine;
[0036] FIG. 7 is a flowchart of the steps performed by the system to
detect
a fault condition within the reactor and to rectify such condition;
[0037] FIG. 8 is a flowchart of the steps performed by the system
when it
is coupled to a storage module;
[0038] FIG. 9 is a flowchart of the steps performed by the system
when it
is coupled to a display module; and
[0039] FIG. 10 is a flowchart of the steps performed by the system when it
is in communication with a remote server.
[0040] The skilled person in the art will understand that the
drawings,
described below, are for illustration purposes only. The drawings are not
intended to limit the scope of the applicants' teachings in anyway. Also, it
will be
appreciated that for simplicity and clarity of illustration, elements shown in
the
figures have not necessarily been drawn to scale. For example, the dimensions
of some of the elements may be exaggerated relative to other elements for
clarity. Further, where considered appropriate, reference numerals may be
repeated among the figures to indicate corresponding or analogous elements.
DESCRIPTION OF VARIOUS EMBODIMENTS
[0041] It will be appreciated that numerous specific details are set
forth in
order to provide a thorough understanding of the exemplary embodiments
described herein. However, it will be understood by those of ordinary skill in
the
art that the embodiments described herein may be practiced without these
specific details. In other instances, well-known methods, procedures and
components have not been described in detail so as not to obscure the
embodiments described herein. Furthermore, this description is not to be
considered as limiting the scope of the embodiments described herein in any
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way, but rather as merely describing the implementation of the various
embodiments described herein.
[0042] One or more systems described herein may be implemented in
computer programs executing on programmable computers, each comprising at
least one processor, a data storage system (including volatile and non-
volatile
memory and/or storage elements), at least one input device, and at least one
output device. For example, and without limitation, the programmable computer
may be a programmable logic unit, a mainframe computer, server, and personal
computer, cloud based program or system, laptop, personal data assistance,
cellular telephone, smartphone, or tablet device.
[0043] Each program is preferably implemented in a high level
procedural
or object oriented programming and/or scripting language to communicate with a
computer system. However, the programs can be implemented in assembly or
machine language, if desired. In any case, the language may be a compiled or
interpreted language. Each such computer program is preferably stored on a
storage media or a device readable by a general or special purpose
programmable computer for configuring and operating the computer when the
storage media or device is read by the computer to perform the procedures
described herein.
[0044] Referring now to FIG.1, FIG. 1 is a block diagram illustrating an
exemplary embodiment of system 100 that manages electrolytic reaction of an
on-demand reactor 102 for generating hydrogen and oxygen gas to be injected
into an internal combustion engine 104 so as to reduce emissions, improve fuel
economy and improve engine performance. System 100 comprises a number of
functional elements including a reactor 102, an engine 104, an engine control
module ("ECM") 106, an electronic control unit ("ECU") 108, a plurality of
sensors
110 coupled to the reactor 102, and a reactor control board ("RCB") 112. The
ECU 108 is the commander or decision-making unit of the system 100. The ECU
108 together with the RCB 112 form the control set (not shown) of the system
100. Upon starting the engine 104, the ECU 108 powers on and receives power
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from the engine's ignition signal. This signal is provided when the ignition
is
turned on.
[0045] After the power-on stage, the system 100 performs a self-
check.
The self-check is a built-in function of the ECU 108's micro-controller (not
shown)
that performs initialization of the ECU 108's input and output pins as well as
initialization of the RCB 112 and the plurality of sensors 110. The system 100
then moves on to perform self-monitoring and operation steps.
[0046] In the first step of self-monitoring steps, the ECU 108
performs a
leak check on the reactor 102. A subroutine is used to detect a leak and
prevent
a false positive. If a leak is detected, the subroutine returns a value
indicating so,
and generates a fault code.
[0047] Next, the ECU 108 performs a temperature check on the reactor
102. A subroutine is used to monitor the reactor 102's temperature and control
the reactor 102's heater (not shown) to an optimal temperature for the reactor
102.
[0048] Next, the ECU 108 performs a temperature check on the water
reservoir (not shown). A subroutine is used to monitor the water reservoir
temperature and control the water reservoir heater to an optimal temperature
for
the water.
[0049] Next, the ECU 108 performs the reactor 102 voltage check. A
subroutine is used to check that the voltage is in the optimal range. The RCB
112
has built-in circuitry to measure and control the voltage. The ECU 108 records
the value and compares it with the optimal range. If the ECU 108 determines
that
the voltage is not within, and cannot be adjusted to, the optimal range, it
returns
a fault code.
[0050] Next, the ECU 108 performs a level check of the water
reservoir. A
subroutine is used to measure the water reservoir level (not shown) connected
to
the reactor 102. The subroutine has 2 levels. If the ECU 108 receives an "add
water" signal for the first level associated with the "operator fill" level,
it returns a
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warning to the operator to top up the tank (not shown). If the ECU 108
receives a
signal for the second level associated with the pump (not shown), the ECU 108
will not allow the pump to turn on, preventing damage to the pump and system
100. The ECU 108 will eventually shut the reactor 102 off to prevent further
damage in the event that no water is added to the reservoir.
[0051] Next, the ECU performs a resistance check on the reactor 102.
A
subroutine is used to measure the resistance of the electrolyte. A sensor
among
the plurality of sensors 110, in contact with the electrolyte, is used to
measure
the resistance. The value can be used to determine the concentration and
conductivity of the electrolyte. This information may be useful in the high
precision gas flow calculation, discussed below.
[0052] After the self-monitoring steps, described above, the system
100
moves on to perform operation steps. The first step is to power up the reactor
102.
[0053] The ECU 108 will determine if the reactor 102 can be powered up
based on the status of the self-monitored checks, above. If the ECU 108 powers
on the reactor 102 and no water is added to the reactor 102, the ECU 108 will
shut the reactor 102 down when it reaches a low electrolyte state. When the
ECU
108 determines that the reactor 102 is ready, it then turns on the reactor
102. To
do so, the ECU 108 sends a signal to the RCB 112 allowing the current to flow
through the reactor 102.
[0054] Then, the ECU 108 performs a reactor 102 amperage check; this
is
part of the self-monitoring subroutine. The subroutine is used to measure the
amperage that the reactor 102 is drawing. The RCB 112 has built in circuitry
to
measure and control the amperage to the reactor 102. The measured amperage
is an indicator that the reactor 102 is operating. The ECU 108 compares the
measured amperage to the optimal amperage and adjusts it accordingly. The
RCB 112 can control the voltage and current to adjust the reactor 102's power
consumption to optimal performance. The ECU 108 controls the RCB 112 and
the reactor 102's temperature for achieving optimal performance.
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[0055] Similar to other steps, subroutines are programmed in the ECU
108's microcontroller to gather and record plurality of sensors 110 data. The
ECU
108 uses the gathered data to measure a plurality of reactor parameters,
thereby
to calculate the reactor performance level or gas production rate while the
reactor
102 is running. To achieve the goal of improving the engine 104's performance,
the ECU 108 calculates the performance of the engine 104 (i.e. determines the
engine performance indicators and priority, as described in more detail below)
by
monitoring a plurality of engine parameters to determine how to adjust the
reactor performance level (or gas production rate) so as to improve the engine
104's performance. The steps associated with this stage of the managing system
100 are illustrated in FIG. 6 and discussed in more detail below.
[0056] Referring now to FIGS 1 and 6, FIG. 6 is a flowchart that
illustrates
basic steps 600 taken by the system 100 to improve the engine 104's
performance. The process begins at step 602. At step 604, the ECU 108
monitors the plurality of reactor parameters by means of monitoring the
plurality
of sensors 110, as described below. At step 606, the ECU 108 determines the
reactor performance level based on the data gathered from the plurality of
sensors 110 in step 604; this is the initial reactor 102 state. At step 608,
the ECU
108 monitors the plurality of engine parameters either directly from the
engine
104, in the event the engine 104 is not equipped with an ECM 106, or from the
data stored within the ECM 106. At step 610, the ECU 108 determines the
engine performance level based on the data gathered in step 608; this is the
initial engine 104 state, or its baseline performance. At step 611, the ECU
108
determines changes that may occur in the determined engine performance level
by continuing to monitor the engine performance level so that it can forecast
a
future engine demand level. Then, at step 612, the ECU 108 determines a gas
production rate or reactor performance level that can improve the engine
performance while the engine is operating at the determined engine performance
level or, if changes in the performance were detected in step 611, while the
engine is operating at the forecast future engine demand level. The reactor
performance level or gas production rate at step 612 is called "ideal reactor
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performance level" as when the reactor 102 operates at this level it can
supply an
amount of gas corresponding to the determined engine performance level at step
610, or, if changes detected at step 611, corresponding to the forecast future
engine demand level, to the engine 104 at exactly the moment the engine 104 is
about to operate at the respective performance or demand level. This is the
algorithm through which the system 100 improves the engine 104's performance
in real time. In other words, the system 100 is always one step ahead of the
engine; the system 100 does not show a reactionary response to what already
has taken place. Finally, at step 614, the ECU 108 through the RCB 112
modifies
at least one of, but not limited to, the electrical current supplied to the
reactor
102, the electrical voltage supplied to the reactor 102, and the temperature
of the
reactor 102 to achieve the ideal reactor performance level.
[0057] The steps described above are repeated while the engine 104 is
running. In other words, the performance of the reactor 102 is being optimized
constantly, by constantly determining a new ideal reactor performance level
corresponding to upcoming engine 104's demand, to continuously improve the
engine 104's performance while the engine 104 is running. In addition to
determining the engine performance level at any moment, the ECU 108
continuously monitors the plurality of engine parameters to determine any
change in the engine performance level and to forecast a future engine demand
level. In other words, the ECU 108 can predict the demand that is going to be
placed on the engine in future. The ECU 108 then optimizes the reactor 102's
performance by commanding it to operate at the ideal reactor performance level
corresponding to the determined engine performance level, if the engine is
still
operating at that level, or the forecast future engine demand level, if the
engine is
about to operate at this level, to improve the engine 104's performance at
real
time, i.e. not showing a reactionary response.
[0058] The initially measured engine performance level is established
as a
baseline, as discussed above. The ECU 108 then calculates the reactor
performance level or gas production rate, as discussed below, for optimizing
the
reactor 102's performance and data logging the reactor performance level
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corresponding to the baseline engine performance level. Thereafter, the ECU
108 monitors the plurality of engine parameters to detect changes in the
engine
performance level, i.e. a sign of change in the engine 104's demand. If the
engine 104's demand and the engine performance level change, the ECU 108
controls the reactor 102 via the RCB 112 to adjust the reactor performance
level
or gas production rate to improve the engine 104's performance. The ECU 108
further forecasts if the changes in the engine performance level or the engine
104's demand are going to continue based on the engine 104's parameters such
as throttle positions, etc. This is the forecasting that takes place at step
611.
[0059] In addition to reading the plurality of engine parameters to
determine a change in the engine 104's demand and the engine performance
level, the ECU 108 also uses the telemetry parameters such as GPS data,
terrain
condition, etc. to better forecast the future engine demand level and the
required
reactor performance level or gas production rate.
[0060] This method allows the ECU 108, in advance, to estimate the
required reactor performance level in preparation for forecast changes in the
engine 104's demand, i.e. the forecast future engine demand level. In other
words, knowing the reactor performance level, the amount of gas being
generated, the engine performance level, and the forecast changes provide the
necessary information to the ECU 108 to estimate and control the reactor
performance level, or gas production rate, as a means for controlling the
actual
amount of gas being delivered to the engine 104. Using this information, in
combination with determining the engine performance level and forecasting the
future engine demand level, results in the ability to adjust the reactor
performance level or amount of gas production in a way that optimizes the
reactor 102's performance ahead of the engine 104's demand. That is, the gas
enters the combustion chamber as the change in the engine performance level
occurs, i.e. when the engine 104 operates at the forecast future engine demand
level, and not afterwards in response to changes.
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[0061]
This also means that the reactor 102 settings are automatically
adjusted so that only the necessary power is used to create the required gas.
For
instance, if only 1 liter of gas is required, the ECU 108 controls the reactor
102
via the RCB 112 to use the minimum power required to produce that amount of
gas. As described below, this operation method of system 100 results in
improving the engine 104's performance, based on the priority of the
performance indicators, while minimizing the reactor 102's power consumption
and optimizing the performance of the reactor 102 while simultaneously
improving the fuel efficiency and reducing emissions.
[0062] The
following paragraphs discuss the aforementioned steps in
more detail.
[0063]
Referring again to FIGS 1 and 6, to calculate the reactor
performance level or gas production rate at step 606, the ECU 108 reads values
on amperage, voltage, electrolyte conductivity and concentration, and
temperature value, i.e. the plurality of reactor and engine parameters, from
the
plurality of sensors 110 at step 604. Each ECU 108 has an in-house calibration
chart programmed into its microcontroller that maps the hydrogen and oxygen
production and parameter values. The data gathered from the plurality of
sensors
110 at step 604 is used to fine tune the calculation performed at step 606 by
comparing the measured values against the baseline values or previous
performance levels. This also has the added benefit that the system 100 does
not need to be equipped with expensive gas flow meters to determine the gas
being delivered to the engine.
[0064]
To further determine a more accurate reactor performance level or
gas production rate, the ECU 108, in addition to using the electrical power
consumed by the reactor 102 (Power- Voltage x Electrical Current), can factor
in for the variance in temperature and variance in concentration of
electrolyte.
Initially, the reactor performance level is determined at a calibration
temperature.
The reactor 102 will inherently heat up on its own and without controlling the
power there is a possibility that the reactor 102 will overheat. When the
power is
CA 02945891 2016-10-20
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limited, the reactor 102's temperature should stabilize. For calibration, the
power
is limited and the reactor 102 is allowed to stabilize. The gas production and
temperature that are measured initially define the reactor 102's baseline for
performance, as referred to above. This means the ECU 108 needs to take into
account an adjustment for temperature in further calculations of the reactor
performance level.
[0065] Consequently, the ECU 108 adjusts the reactor performance
level
or gas production rate, calculated at step 606, by means of taking into
account
amperage, voltage, temperature, and/or electrolyte concentration. Thereafter,
the
ECU 108 returns this adjusted value as the reactor performance level or gas
production rate.
[0066] The calculations at step 606 may be based on one of, but not
limited to, the plurality of sensors 110 monitoring the plurality of reactor
parameters, depending on the process or calculation.
[0067] Before moving on to the next step of determining the engine
performance level, step 610, the importance of monitoring the electrolyte
concentration and conductivity should be highlighted. As discussed above, the
concentration is monitored at step 604 as part of determining the reactor
performance level or gas production rate at step 606; the concentration
changes
during operation and will have a small effect on the gas production. In
addition,
the monitoring of electrolyte concentration is used to check that the
electrolyte is
not lost or not crystalized and to confirm that water has been added to the
reactor
102 when required. The concentration will vary as the water is converted to
gas.
If the concentration is out of a predetermined range and the ECU 108 cannot
correct the issue by demanding the pump to add water, the ECU 108 indicates a
fault and prevents the system 100 from further operation. The electrolyte is a
catalyst and should not get used up. Crystallization and electrolyte loss will
lead
to a unit failure.
[0068] As discussed, the ECU 108 also uses monitoring of the
electrolyte
concentration to determine the reactor performance level (or the amount of gas
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being generated) at step 606. Gas production calculations based on the power
consumption (derived from those plurality of sensors 110 measuring voltage and
amperage, through the following formula Power- Voltage x Electrical Current)
are more accurate when adjusted by introducing the concentration and
conductivity of the electrolyte into the equation. As the water is decomposed
into
gas, the concentration level will change. This change affects the gas
production
to a certain degree.
[0069] Moving to the next step of determining the engine performance
level, step 610, the ECU 108 interacts with the engine 104, or the ECM 106,
using built-in circuitry to monitor the plurality of engine parameters at step
608,
discussed below. The plurality of engine parameters is monitored in order to
observe the engine 104's operation and performance changes. This allows the
ECU 108 to determine the ideal reactor performance level required for
improving
the engine performance. Changes, determined in step 611, in each of the
monitored plurality of engine parameters at step 608 indicate whether the
engine
104 needs to supply more power or less power, i.e. whether the engine 104's
demand or the engine performance level is increasing or decreasing.
Determining changes can be used to forecast a future engine demand level. It
is
also upon determining a change in the engine 104's demand or the engine
performance level that the ECU 108, at step 614, controls the RCB 112 to
adjust
the reactor performance level or gas production rate to improve the engine
104's
performance when the engine 104 is in fact operating at the forecast future
engine demand level.
[0070] The ECU 108 monitors either through the ECM 106, if
available, or
directly, at least one of, but not limited to, the following non-exhaustive
list of the
plurality of engine parameters at step 608 to determine the engine performance
at step 610 and to determine a changes in the engine performance level to
forecast a future engine demand level at step 611: odometer, vehicle speed,
engine speed, fuel consumption, fuel rate, mass air pressure, mass air flow,
mileage, distance, fuel rate, exhaust temperature, NO sensors, CO2 sensors, 02
sensors, engine instantaneous fuel economy, engine average fuel economy,
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engine inlet air mass flow rate, engine demand¨percent torque, engine percent
load at current speed, transmission actual gear ratio, transmission current
gear,
engine cylinder combustion status (all cylinders), engine cylinder knock level
(all
cylinders), after treatment intake NO, sensor preliminary FMI (all banks),
etc.
[0071] As discussed, the ECU 108 controls the amount of gas delivered to
the engine 104 intake by determining the engine performance level in order to
improve the combustion process. The ECU 108 is also able to recalibrate some
of the plurality of engine parameters, not changing the programming, so that
the
ECM 106 can adapt to addition of the gasses to the combustion chamber.
Moreover, as discussed below, it should be noted that the ECU 108 records the
reactor performance level and engine performance level for future analysis and
improvement of the system 100.
[0072] Now that the ECU 108 has determined the engine performance
level at step 610, and the forecast future engine demand level at step 611, it
needs to control the RCB 112 to adjust the reactor performance level, or gas
production rate, to improve the engine 104's performance while the engine 104
is
operating at the determined engine performance level or, due to changes
determined at step 611, operating at the forecast future engine demand level.
The ECU 108 uses the gathered data from steps 604-611 to determine an ideal
reactor performance level at step 612 and send the determined ideal reactor
performance level to the RCB 112 at step 614. In addition to the data gathered
from the engine 104 and the reactor 102, the ECU 108 also uses telemetry
parameters such as GPS data, terrain condition, etc. in determining and
forecasting the current and future engine 104's demands, corresponding engine
performance levels, and the corresponding ideal reactor performance level.
[0073] The reactor 102 now needs to operate according to the
determined
ideal reactor performance level at step 612. The RCB 112 is designed to
controls
the reactor in order to control and adjust the amount of gas being delivered
to the
engine. The RCB 112 has a custom built microcontroller controlling, but not
limited to, a pulse width modulator (PWM) and a current sensor. It may also
have
CA 02945891 2016-10-20
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a voltage and/or a frequency modulator along with corresponding sensors. At
step 614, the RCB 112 can measure and control the reactor 102's performance
through integrated circuitry based on instructions received from the ECU 108.
The RCB 112 also has a humidity-temperature sensor and a communication link,
discussed below.
[0074] At step 604, the RCB 112 monitors the amperage as part of the
self-monitoring subroutine. The RCB 112 measures the power that the reactor
102 is drawing and adjusts the amperage using the PWM to meet the power
requirements instructed by the ECU 108. The RCB 112 raises or lowers the
amperage to control the reactor performance level or gas production rate, as
determined by the ECU 108, provided the power is within the limits. The RCB
112 also monitors the reactor 102 temperature, as part of the self-monitoring
subroutine, through an integrated temperature sensor. The RCB 112 and the
ECU 108 interacts to control the heater and fan to adjust the reactor
temperature.
[0075] An increased temperature aids in the electrolytic process of water
to a certain degree. As the temperature rises, the decomposition potential,
the
energy required for splitting water into gas, is lowered. The RCB 112 uses
this
information to raise the temperature if higher reactor performance level or
more
gas production rate is needed without increasing the amperage. By increasing
the temperature rather than the amperage, the power drawn from the engine 104
can be reduced and thereby the engine 104's performance or efficiency is
increased, as discussed below. Further, monitoring the temperature prevents
the
reactor 102 from overheating.
[0076] In summary, the ECU 108, in steps 602-614, interacts with the
engine 104, or ECM 106, the plurality of sensors 110 and RCB 112 to determine
the reactor performance level and engine performance level. The ECU 108
controls the RBC 112 to control the pulse width modulation circuit (not shown)
to
control the amount of current available to the reactor 102 and thereby to
adjust
the reactor performance level or gas production rate to improve the engine
104's
performance while the engine 104 is operating at the determined engine
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performance level or forecast future engine demand level. This adjusted
reactor
performance level is referred to as the ideal reactor performance level.
[0077] It should be noted that, as discussed, the ECU 108 is the
commander or major decision-making unit of the system 100. In other words, the
RCB 112 is a slave to the ECU 108. However, the RCB 112 is equipped with a
communication link as well. Through the communication link, the RCB 112 can
gather other auxiliary information to provide further control in the event the
ECU
108 is not part of the system 100.
[0078] Finally, when the reactor 102 is not required to operate
anymore,
the ECU 108 performs a shut down cycle. Before turning the unit off, the ECU
108 determines the reactor 102 electrolyte level and reservoir water level. If
the
water level is low, the ECU 108 indicates to the operator to fill the water
reservoir. The ECU 108 will fill the reactor provided there is sufficient
water in the
reservoir. The cycle has a timer to allow the reactor to settle; the
electrolyte level
will change slightly after operation. The ECU 108 has a shut down cycle that
uses an internal battery to power some functions to prepare the system 100 for
immediate operation next time it is turned on. The shut down cycle is
initiated
when there is no longer an ignition signal powering the ECU 108.
[0079] As discussed, the reactor performance level or gas
production rate
is directly related to the power that the reactor 102 draws from the engine
104 to
generate gas. Knowing the reactor performance level, the ideal reactor
performance level, and the engine performance level, or the forecast future
engine demand level, will allow the system 100 to minimize the parasitic power
loss from the engine 104. The reactor 102 uses a portion of the power produced
by the engine 104 to run. When the amount of gas generated by the reactor 102
is more than the demand to meet the real time engine performance level, the
reactor 102 is using more power from the engine 104 than is necessary. This
adds to the parasitic energy loss. Since the system 100 can adjust the reactor
performance level according to the real time engine performance level, this
parasitic loss can be minimized. By controlling and optimizing the reactor
102's
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performance, when the engine performance level does not demand a higher gas
production rate from the reactor 102, the system 100 places less load on the
engine 104. In other words, the system 100 achieves one of the objectives of
this
invention, namely to reduce emissions and improve fuel efficiency
simultaneously
while minimizing the power consumption of the reactor 102.
[0080] Referring now to FIGS 1 and 7, FIG. 7 is a flowchart that
illustrates
basic steps 700 taken by the system 100 to detect faults within the system
100.
The process begins at step 702. At step 704, the ECU 108 gathers data on the
plurality of reactor parameters by means of monitoring the plurality of
sensors
110. At step 706, the ECU 108 checks for an occurrence of at least one of, but
not limited to, the plurality of reactor parameters existing outside a normal
operating range based on the data gathered from the plurality of sensors 110
in
step 704. At step 708, if the ECU 108 determines that at least one of the
plurality
of reactor parameters is outside a normal operating range, it moves to step
710.
Otherwise, it moves back to step 704 to monitor the plurality of reactor
parameters again. At step 710, the ECU 108 orders the ROB 112 to regulate the
reactor 102 in response to the occurrence detected at step 708.
[0081] The ECU 108 has the intelligence to use the information it
gathers
at step 704 to determine whether the unit is inside the normal operating
conditions or not. The ECU 108 has the ability to change operational
parameters
to correct fault conditions, when needed, at step 710. The ECU 108 has the
logic
to determine if the changes to correct the fault(s) are having an effect or
not. The
ECU 108 fault detection is designed to protect the engine 104 from being
damaged as well as the system 100 itself. The fault detection is designed in a
fail-safe manner. The ECU 108 programming also has built-in corrective actions
to be taken to keep the system 100 operational for as long as possible,
without
causing damage, if a fault occurs. At step 710, the ECU 108 shuts the reactor
102 off if the corrective actions are not having the desired effect to prevent
damage to the engine 104 or reactor 102.
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[0082] The plurality of reactor parameters that are monitored by the
ECU
108 at step 704 comprises the following non-exhaustive list: water tank level,
electrolyte level, supplied electrical voltage, supplied electrical current,
water tank
temperature, reactor temperature, reactor leakage, water pump, gas flow,
relative
humidity, conductivity of electrolyte, resistance of electrolyte,
concentration of
electrolyte, etc.
[0083] At step 704, the ECU 108 monitors the water tank level and
provides indication when water needs to be added to the reservoir of the
system
100. This also serves to protect the water pump from running when there is not
enough water in the tank. The ECU 108 eventually shuts the reactor 102 off at
step 710 to prevent further damage in the event that no water is added to the
reservoir.
[0084] At step 704, the ECU 108 monitors the reactor 102 electrolyte
level
and will add water to the reactor 102 when needed. The ECU 108 eventually
shuts the system 100 off at step 710 in the event that no water is added to
the
reactor 102.
[0085] At step 704, the ECU 108 monitors the electrolyte
concentration.
The concentration is also monitored as part of determining the reactor
performance level or the amount of gas being generated, as discussed above.
This monitoring, at step 704, is also used to check that the electrolyte is
not
crystallizing and to confirm that water has been added to the reactor 102 when
required. The concentration will vary as the water is added to the reactor 102
or
converted to gas. If the concentration is out of a predetermined range and the
ECU 108 cannot correct the issue, the ECU 108 indicates a fault at step 710.
[0086] At step 704, the ECU 108 measures the voltage to determine, at
step 706, how much voltage is available before the reactor 102 is powered up.
It
also determines the power the reactor 102 is drawing and ensures the reactor
102 does not drain the vehicle battery in the event that the engine 104's
alternator fails or if the ignition is left on without the engine 104 running.
If the
CA 02945891 2016-10-20
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voltage is outside the working range, the ECU 108 shuts the reactor 102 off
and
indicates a fault at step 710.
[0087] At step 704, the ECU 108 measures the current to determine,
at
step 706, the power the reactor 102 is drawing and to ensure that the reactor
102
is operating at the specified amperage for the desired reactor performance
level
or gas production rate. As discussed above, this is one of the ways that the
ECU
108 controls the reactor performance level or the gas production rate. If the
amperage is outside the working range, the ECU 108 shuts the reactor 102 off
and indicates a fault at step 710.
[0088] At step 704, the ECU 108 measures the water tank temperature to
ensure that the water is liquid and not solid. If, at step 706, the
temperature is
determined to be below 8 C, the ECU 108 turns on the tank heater to bring the
water to operational temperature at step 710.
[0089] At step 704, the ECU 108 measures the reactor 102 temperature
to
monitor its performance and ensure the reactor 102 does not over-heat. At step
706, the ECU 108 determines if the temperature is optimal. The ECU 108 turns
on the reactor 102 heater to bring it up to optimal temperature at step 710.
It also
shuts the reactor 102 down in the event that the reactor 102 starts to
overheat.
[0090] At step 704, the ECU 108 monitors the reactor 102 for leaks.
The
ECU 108 at step 706 determines if the leak is a false positive or an actual
leak. If
the leak is determined to be true the ECU 108 shuts down the reactor 102 and
indicates a fault at step 710.
[0091] Referring now to FIG. 2, FIG. 2 is a block diagram
illustrating
another exemplary embodiment of the system 100. System 200 comprises a
number of functional elements including a reactor 202, an engine 204, an
engine
control module ("ECM") 206, an electronic control unit ("ECU") 208, a
plurality of
sensors 210 coupled to the reactor 202, a reactor control board ("RCB") 212,
and
a storage module 214 coupled to the ECU 208. Other than the storage module
214, other components are similar to those described above and illustrated in
CA 02945891 2016-10-20
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FIG. 1. As a result, these components are referred to using reference numerals
corresponding to FIG. 1.
[0092] The storage module 214 is configured to store the plurality of
reactor parameters, the plurality of engine parameters, the reactor
performance
level and the engine performance level. The ECU 108 uses the storage module
214 to log and record data for further analysis to create performance
improvements. The ECU 108 also logs the data for future reporting.
[0093] Referring now to FIGS 1, 2 and 8, FIG. 8 is a flowchart that
illustrates basic steps 800 taken by the system 100 or 200 to store the
plurality of
reactor parameters, the plurality of engine parameters, the reactor
performance
level, and the engine performance level. The process begins at step 802. At
step
804, the ECU 108 gathers data on the plurality of reactor parameters by means
of monitoring the plurality of sensors 110 or 210. At step 806, the ECU 108
determines the reactor performance level based on the data gathered from the
plurality of sensors 110 in step 804. At step 808, the ECU 108 gathers data on
the plurality of engine parameters. At step 810, the ECU 108 determines the
engine performance level based on the data gathered in step 808. Finally, at
step
812, the ECU 108 stores the monitored plurality of reactor parameters and
plurality of engine parameters along with the determined reactor performance
level and engine performance level in the storage module 214.
[0094] Referring now to FIG. 3, FIG. 3 is a block diagram
illustrating
another exemplary embodiment of system 100. System 300 comprises a number
of functional elements including a reactor 302, an engine 304, an engine
control
module ("ECM") 306, an electronic control unit ("ECU") 308, a plurality of
sensors
310 coupled to the reactor 302, a reactor control board ("RCB") 312, and a
display module 314 coupled to the ECU 308. Other than the display module 314,
other components are similar to those described above and illustrated in FIG.
1.
As a result, these components are referred to using reference numerals
corresponding to FIG. 1.
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[0095] Referring to FIGS 1 and 3, the display module is configured
to
visually display a performance indicator based on the plurality of reactor
parameters, the plurality of engine parameters, the reactor performance level
and
the engine performance level. The display module 314 is the main focal point
for
the operator to interface with system 100. The information and communication
are controlled by the ECU 108. The display module 314 updates the driver on
the
performance of the reactor 102 and the engine 104. It also allows the operator
to
control and setup specific parameters for the reactor 102. Different customers
may have different applications for system 100 and the display module 314
provides the interaction for customizing the available parameters to meet
their
needs. Further, the ECU 108 can communicate with the display module 314 to
display the necessary information to a user to keep the system 100 in optimal
work order or to inform the user to perform service on the system 100.
[0096] Referring now to FIGS 1, 3 and 9, FIG. 9 is a flowchart that
illustrates basic steps 900 taken by the system 100 or 300 to visually display
the
plurality of reactor parameters, the plurality of engine parameters, the
reactor
performance level, and the engine performance level. The process begins at
step
902. At step 904, the ECU 108 gathers data on the plurality of reactor
parameters by means of monitoring the plurality of sensors 110 or 310. At step
906, the ECU 108 determines the reactor performance level based on the data
gathered from the plurality of sensors 110 in step 904. At step 908, the ECU
108
gathers data on the plurality of engine parameters. At step 910, the ECU 108
determines the engine performance level based on the data gathered in step
908. Finally, at step 912, the ECU 108 can visually display one or many of the
monitored plurality of reactor parameters and the plurality of engine
parameters
along with determined reactor performance level and engine performance level
via the display module 314.
[0097] Referring now to FIG. 4, FIG. 4 is a block diagram
illustrating
another exemplary embodiment of system 100. System 400 comprises a number
of functional elements including a reactor 402, an engine 404, an engine
control
module ("ECM") 406, an electronic control unit ("ECU") 408, a plurality of
sensors
CA 02945891 2016-10-20
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410 coupled to the reactor 402, a reactor control board ("RCB") 412, and a
remote server 414 in communication with the ECU 408. Other than the remote
server 414, other components are similar to those described above and
illustrated in FIG. 1. As a result, these components are referred to using
reference numerals corresponding to FIG. 1.
[0098] Referring to FIGS 1 and 4, the ECU 108 is able to transmit
performance logs and other specified data to a portal to be compiled and put
into
a report. The data that is logged and used by the ECU 108 during the initial
trip to
improve the performance of the engine 104 and optimize the performance of the
reactor 102 is uploaded to the remote server 414 at the end of the trip. The
received data is analyzed to determine if any improvements can be made to the
logic of the system 100 to improve the engine 104's performance. A human
operator or a computer program is responsible for conducting said analysis.
The
improvements may be applied to other ECUs, associated with other engines, in
communication with the remote server 414 that have similar conditions. The
existence of the remote server 414 is crucial in report generating.
[0099] Moreover, the ECU 108 is not limited to transmitting data only
at
the end of each trip. The ECU 108 can set a data transmission interval during
each trip and send data to the remote server 414 accordingly. The received
data
is stored in the remote server 414 and a trend of historical data is created
for
every ECU 108 in communication with the remote server 414. Upon receiving the
data, an analysis is conducted. The data is compared to historical trends and
data received from other ECUs that are in communication with the remote server
414. If the human operator or the computer program determines that an
improvement to the performance of the engine 104 and the reactor 102 is
available, based on the aforementioned analysis, the remote server 414 sends
instructions to the ECU 108 in order to improve the engine 104 and the reactor
102 performance. If the remote server 414 determines that the performance
improvement is also applicable to other ECUs associated with other engines in
communication with the remote server 414, it sends similar instructions to
those
ECUs as well.
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[00100] In order to transmit and receive data to and from the remote
server
414, the ECU 108 needs to establish a connection with the remote server 414.
The ECU 108 is able to connect through multiple methods to transfer the
correct
data and information. The ECU 108 has built-in radios, such as GPRS, WIFI,
and/or Bluetooth, for communication with external devices for the interaction
and
transfer of data. The ECU 108 has USB ports too for wired communications.
Further, after each instance of data transmission, the ECU 108 receives and
sends a confirmation that data has been transmitted successfully.
[00101] Referring now to FIGS 1, 4 and 10, FIG. 10 is a flowchart that
illustrates basic steps 1000 taken by managing system 100 or 400 to
communicate with the remote server 414 and transmit the plurality of reactor
parameters, the plurality of engine parameters, the reactor performance level,
and the engine performance level. The process begins at step 1002. At step
1004, the ECU 108 gathers data on the plurality of reactor parameters by means
of monitoring the plurality of sensors 110 or 410. At step 1006, the ECU 108
determines the reactor performance level based on the data gathered from the
plurality of sensors 110 in step 1004. At step 1008, the ECU 108 the plurality
of
engine parameters. At step 1010, the ECU 108 determines the engine
performance level based on the data gathered in step 1008. At step 1012, the
ECU 108 transmits the monitored plurality of reactor parameters and plurality
of
engine parameters along with determined reactor performance level and engine
performance level to the remote server 414. Finally, at step 1014, the remote
server 414, after conducting the above discussed analysis on the received
data,
transmits an ideal reactor performance level and instructions on how to
achieve
the ideal reactor performance level to the ECU 108. This in turn results in
improved reactor 102's and engine 104's performance.
[00102] Referring now to FIG. 5, FIG. 5 is a block diagram
illustrating
another exemplary embodiment of system 100. System 500 comprises a number
of functional elements including a reactor 502, an engine 504, an engine
control
module ("ECM") 506, an electronic control unit ("ECU") 508, a plurality of
sensors
510 coupled to the reactor 502, a reactor control board ("RCB") 512, a storage
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module 514 coupled to the ECU 508, a display module 516 coupled to the ECU
508, and a remote server 518 in communication with the ECU 508. This
embodiment is a combination of embodiments represented in FIGS 1-4.
[00103] In another exemplary embodiment of system 100, the ECU 108
can
adjust the reactor performance level or gas production rate in a way to
selectively
optimize engine performance indicators. Engine performance indicators are
calculated using the plurality of engine parameters, discussed above. Engine
performance indicators are targets that the system 100 wants to achieve. For
instance, engine performance indicators are, but not limited to, fuel
efficiency,
emissions, engine torque, and engine horsepower. Depending on which engine
performance indicators are selected, the system 100 maximizes the selected
engine performance indicators according to the priority assigned to the
selected
engine performance indicators.
[00104] Referring now to FIGS 1 and 3, the user selects the engine
performance indicators that he/she desires to optimize and ranks them based on
a priority that she/he has in mind through the display module 314. The ECU 108
adjust the reactor performance level or gas production rate to optimize each
of
the selected engine performance indicators ranked from highest to lowest.
Consider the following example.
[00105] For instance, there are situations where emissions will out rank
fuel
economy. Consider a case that the engine performance indicators are ordered
as: 1) emissions reduction and 2) fuel savings. In this example, the ECU 108
monitors emissions and adjusts the reactor performance level or gas production
rate to reduce emissions first. It continues to adjust the reactor performance
level
or gas production rate to reduce emissions up to the point of reaching a
plateau
or just before emissions begin to rise again. This is the optimum point. At
this
point, the ECU 108 focuses on reducing the fuel consumption, the engine
performance indicator ranked second in priority. As the fuel consumption is
being
reduced, emissions are still being monitored to track any changes there. Once
the fuel economy is optimized, a comparison between the two different reactor
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performance levels or gas production rates corresponding to optimizing
emissions and fuel economy, respectively, is made to find a best fit model
that
can optimize efficiency in all aspect of the engine performance. This found
best
fit model is the ideal reactor performance level associated with
simultaneously
optimizing selected engine performance indicators. This method for improving
the engine 104's and reactor 102's performance can be used with one or
multiple
engine performance indicators.
[00106] Numerous specific details are set forth herein in order to
provide a
thorough understanding of the exemplary embodiments described herein.
However, it will be understood by those of ordinary skill in the art that
these
embodiments may be practiced without these specific details. In other
instances,
well-known methods, procedures and components have not been described in
detail so as not to obscure the description of the embodiments. Furthermore,
this
description is not to be considered as limiting the scope of these embodiments
in
any way, but rather as merely describing the implementation of these various
embodiments.
