Limp home capable dual fuel engine and machine using same

• US 8,944,033 B2
• Filed: 09/07/2012
• Issued: 02/03/2015
• Est. Priority Date: 09/07/2012
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Coldren, Dana R., Steffen, Joshua W., Uhland, Gregg W., Garman, Brian K., Stockner, Alan R.
• Primary Examiner(s): Gimie, Mahmoud
• Application Number:
  US13/606,422
• Publication Number:
  US 20140069386A1
• Time in Patent Office: 879 Days
• Field of Search: 123/27.GE, 123/525, 123/526, 123/529, 123/575, 123/577, 123/481, 123/198.F, 701/102, 701/107, 701/112, 701/114
• US Class Current: 123/525
• CPC Class Codes: F02B 7/02 the fuel in the charge being liquid
• CPC Class Codes: F02D 19/061 by controlling fuel injectors
• CPC Class Codes: F02D 19/0623 Failure diagnosis or prevention; Safety measures; Testing
• CPC Class Codes: F02D 19/0647 the gaseous fuel being liquefied petroleum gas [LPG], liquefied natural gas [LNG], compressed natural gas [CNG] or dimethyl ether [DME]
• CPC Class Codes: F02D 19/0689 for in-cylinder direct injection
• CPC Class Codes: F02D 19/0694 operating with a plurality of fuels
• CPC Class Codes: F02D 19/081 Adjusting the fuel composition or mixing ratio; Transitioning from one fuel to the other
• CPC Class Codes: F02D 2041/227 Limping Home, i.e. taking specific engine control measures at abnormal conditions
• CPC Class Codes: F02D 41/0025 Controlling engines characterised by use of non-liquid fuels, pluralities of fuels, or non-fuel substances added to the combustible mixtures
• CPC Class Codes: F02D 41/0027 the fuel being gaseous non-electrical control F02D19/02
• CPC Class Codes: F02D 41/021 Introducing corrections for particular conditions exterior to the engine conjoint control of vehicle sub-units for propelling the vehicle B60W30/18
• CPC Class Codes: F02M 21/02 for gaseous fuels
• CPC Class Codes: Y02T 10/30 Use of alternative fuels, e.g. biofuels

Abstract

A dual fuel engine powers a machine by burning natural gas and liquid diesel fuel. When operating in a low load mode, some of the engine cylinders are fueled with a high ratio of diesel/gas, and the remaining cylinders are unfueled. When operating in a high load mode, all of the engine cylinders are fueled with a low ratio of diesel/gas. When operating in a limp home mode, the fuel injectors are configured to inject only diesel fuel into all of the plurality of engine cylinders.

Claims

1. A machine comprising:

a machine body supported by a conveyance;

a dual fuel compression ignition engine having a plurality of cylinders, being attached to the machine body and operably coupled to the conveyance;

a dual fuel system operably coupled to supply the dual fuel compression ignition engine with liquid diesel fuel and natural gas fuel from a single fuel injector directly into respective engine cylinders;

an electronic controller in control communication with the dual fuel system and having a low load algorithm, a high load algorithm and a limp home algorithm each configured to control operation of the dual fuel system;

wherein the low load algorithm is configured to inject a high ratio diesel fuel to natural gas fuel into less than all of the plurality of engine cylinders in each engine cycle, and inject no diesel fuel or natural gas fuel into the remaining engine cylinders;

wherein the high load algorithm is configured to inject a low ratio of diesel fuel to natural gas fuel into all of the plurality of engine cylinders; and

wherein the limp home algorithm is configured to inject only diesel fuel into all of the plurality of engine cylinders.

2. The machine of claim 1 wherein the low load algorithm is configured to change among different sets of engine cylinders that are fueled and cut out in different engine cycles.

3. The machine of claim 1 wherein the high load algorithm is configured to inject natural gas fuel at a medium pressure and inject liquid diesel fuel at a medium high pressure;

and

the limp home algorithm is configured to inject liquid diesel fuel at a high pressure.

4. The machine of claim 1 wherein the dual fuel system includes a gaseous fuel common rail, a cryogenic liquefied natural gas tank and a conditioning module for controlling pressure in the gaseous fuel common rail.

5. The machine of claim 4 wherein the low load algorithm is configured to change among different sets of engine cylinders that are fueled and cut out in different engine cycles.

6. The machine of claim 4 wherein the high load algorithm is configured to inject natural gas fuel at a medium pressure and inject liquid diesel fuel at a medium high pressure;

and

the limp home algorithm is configured to inject liquid diesel fuel at a high pressure.

7. The machine of claim 6 wherein the low load algorithm is configured to change among different sets of engine cylinders that are fueled and cut out in different engine cycles.

8. A method of operating a machine that includes a machine body supported by a conveyance;

a dual fuel compression ignition engine having a plurality of cylinders, being attached to the machine body and operably coupled to the conveyance;

a dual fuel system operably coupled to supply the dual fuel compression ignition engine with liquid diesel fuel and natural gas fuel from a single fuel injector directly into respective engine cylinders; and

an electronic controller in control communication with the dual fuel system and having a low load algorithm, a high load algorithm and a limp home algorithm each configured to control operation of the dual fuel system, the method comprising the steps of;

idling the machine;

moving the machine with a load;

limping the machine home;

the idling step includes fueling some, but not all, of the cylinders with a high ratio of liquid diesel fuel to natural gas fuel;

the moving step includes fueling all of the cylinders with a low ratio of liquid diesel fuel to natural gas fuel; and

the limping step includes fueling all of the cylinders exclusively with liquid diesel fuel.

9. The method of claim 8 wherein the idling step includes changing among different sets of engine cylinders that are fueled and cut out in different engine cycles.

10. The method of claim 8 wherein moving step includes injecting natural gas fuel at a medium pressure and injecting liquid diesel fuel at a medium high pressure;

and

the limping step includes injecting liquid diesel fuel at a high pressure; and

returning liquid diesel fuel from the fuel injectors back to tank at a low pressure during all of the idling, moving and limping steps.

11. The method of claim 8 including the steps of storing liquefied natural gas in a cryogenic tank;

controlling gas pressure in a gaseous fuel common rail with a conditioning module fluidly connected to the cryogenic tank;

supplying gaseous fuel to the fuel injectors from the gaseous fuel common rail; and

supplying liquid diesel fuel to the fuel injectors from a liquid fuel common rail.

12. The method of claim 11 wherein the idling step includes changing among different sets of engine cylinders that are fueled and cut out in different engine cycles.

13. The method of claim 11 wherein moving step includes injecting natural gas fuel at a medium pressure and injecting liquid diesel fuel at a medium high pressure;

and

the limping step includes injecting liquid diesel fuel at a high pressure; and

returning liquid diesel fuel from the fuel injectors back to tank at a low pressure during all of the idling, moving and limping steps.

14. The method of claim 13 wherein the idling step includes changing among different sets of engine cylinders that are fueled and cut out in different engine cycles.