The operating principle of a diesel generator set can be summarized as a three-stage energy conversion process: “chemical energy → mechanical energy → electrical energy,” with the core being the precise coordination between the diesel engine and the generator. During system startup, the linear motion generated by the combustion of diesel within the cylinder is converted into rotational power via the crank-connecting rod mechanism, which then drives the generator rotor to cut magnetic field lines and generate electricity. This entire process involves an integrated application of thermodynamics, electromagnetism, and automatic control technology.
Compression ignition is the key distinguishing feature of a diesel engine compared to a gasoline engine. During the compression stroke, when the piston compresses the air to 1/18 of its original volume, the cylinder temperature instantly rises above 500°C, the threshold for diesel self-ignition. At this point, micron-level atomized diesel is injected into the combustion chamber at 250 bar pressure via a common rail injection system. The fuel mist undergoes intense oxidation in the high-temperature and high-pressure environment, releasing energy that drives the piston to generate a torque of 1200–1500 N·m. This design achieves a thermal efficiency of 45% (compared to around 30% for gasoline engines) and, with turbocharging technology, increases intake air density by 2–3 times, significantly enhancing power output.
Once power is transmitted to the generator, the rotor’s electromagnetic field interacts with the stator windings. With the combined effect of rare-earth permanent magnets and a doubly-fed excitation system, the AVR voltage regulation module can dynamically adjust the excitation current using a PID algorithm, ensuring that the output voltage remains stable within 400V ±2%, even when rotational speed fluctuates by ±5%. Notably, modern generator sets incorporate third-harmonic winding compensation technology, limiting voltage sag to within 8% when subjected to a 100% sudden load increase and reducing recovery time to just 0.3 seconds.
The intelligent control system acts as the generator set’s neural network, integrating a 32-bit microprocessor that processes data from over 200 sensors in real time. When detecting anomalies such as abnormal oil viscosity (e.g., 15W-40 oil viscosity dropping below 10 cSt) or cylinder block vibration exceeding 7 mm/s², the protection circuit executes load shedding and shutdown within two electrical cycles. Operational data from an offshore drilling platform indicate that the system achieves a fault prediction accuracy of 92%, preventing unplanned shutdowns that could otherwise result in losses of tens of thousands of dollars per hour.
In practical applications, these generator sets exhibit adaptive adjustment capabilities. As a backup power source for data centers, for instance, the system can complete startup, acceleration, and pressure buildup within 10 seconds upon grid failure, automatically adjusting power output in response to IT equipment load variations. Its proprietary “economic cruise mode” dynamically optimizes the fuel supply curve based on load percentage, achieving a minimum fuel consumption rate of 205 g/kWh in the 50–80% load range, a 12% improvement over traditional operation modes. Additionally, the exhaust heat recovery unit increases overall energy efficiency to 82%, reducing exhaust gas temperature from 550°C to below 150°C, striking a balance between environmental sustainability and energy efficiency.