CARMEL Genset dual fuel ECU – powerd by AI based DF combastion detection model
A Retrofit Solution for Diesel Gensets
Product Overview
CARMEL Genset ECU Integration allows dual fuel use in diesel gensets.
The system delivers precise, real-time monitoring and control. Tailored for advanced dual fuel abnormal combustion detection and prevention, the solution uses multiple vibration sensors and adaptive algorithms to safeguard engine health and maximize performance.
With seamless ECU integration, the retrofit enhances operational reliability and enables effective engine management through direct sensor-to-controller feedback.
In order to develop a realistic economic model for dual-fuel retrofitting of small and medium size engines, the key approach is the use of fumigation – SPI (single point injection) integrated on the engines air intake.
The main drawback of this fuel injection strategy is that it exposes the engine to abnormal combustion events, primarily due to the octane limitations and excessive cooling effect of alternative fuels. The Carmel engine controller is designed precisely to solve this problem.
Benefits
- Non-invasive installation leverages existing engine structure and wiring
- Supports stable operation with alternative fuels, enabling fuel flexibility
- Immediate detection and response to knocking phenomena, reducing risk of engine damage
- Seamless ECU integration – enables direct data transmission from knock sensors to the genset controller
- Compatible with a wide range of diesel genset architectures
Application
Designed for both inline and V-type genset engines with operating speeds between 1500 and 1800 rpm and power outputs up to 1000 kW.
Up to 4 vibration sensors can be flexibly deployed, with sensor assignments optimized for knock detection across specific cylinders.
The solution is ideal for retrofit projects and supports both standalone and integrated modes.
Our Technology – D.F. ECU with AI based combustion detection feedback
At the core of our solution is a combustion detection model specially trained for dual fuel systems.
The system dynamically controls the blending of diesel and alternative fuels, while using the AI model to avoid harmful combustion zones. Unlike other dual fuel systems that rely on expensive cylinder pressure sensors or major engine modifications, our controller uses advanced machine learning and peripheral sensors to self-calibrate and optimize combustion in real time. This allows for:
- Plug-and-play integration on most diesel engines (SPI/PFI)
- Dramatic reduction in diesel use – up to 60%
- Elimination of costly sensor infrastructure
- Lower total cost of ownership and faster deployment
- Fuel flexibility – Ethanol, Methanol, Methane
- Abnormal combustion detection
- DF knocking | Misfire | DF ROHR