Hydrogen generating apparatus and components therefor

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To - Initiation Interval

U- Voltage

U-Minimum ACCeptable Voltage Y - COndition Satisfied

N - COndition NON Satisfied ECM - Emission COntrol MOCule OOP-Optimum Output Parameters (E.G. Voltage / Current)

SPS-Supported Parameter Set (Set of Variables Monitored by the ECU - E.G. RPM/Speed/Fuel Rate) Display Display

Check ECM

COnnection

CALCULATE Display

See next page See next page

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See previous page See previoUS page

Calculate PI

Display PII

Display

SOP, Failure,

ReadinDut

GOP - Generator Operating Parameters (E.G. Voltage) PII - Performance Impact indicator (e.g. Fuel Savings) SOP, System Operating Parameter K

(E.G. Pump Voltage, Vac, Switch Signal) NOR, Normal Operating Range for Parameter K

FIG. 4B

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HYDROGEN GENERATING APPARATUS SUMMARY OF THE INVENTION AND COMPONENTS THEREFOR The present invention is directed to a hydrogen generating System for use in internal combustion engines for increasing

This is a continuation-in-part of U.S. application Ser. No. the efficiency of the engine and decreasing emissions from 09/106,549 filed Jun. 29, 1998, the contents of which are the engine. The hydrogen generating System of the present hereby incorporated by reference in their entirety. invention comprises an electrolysis cell for generating FIELD OF THE INVENTION hydrogen and oxygen gases by electrolysis of an aqueous The present invention is directed to a hydrogen generating Solution, a power Source for providing electrical power to apparatus and in particular a hydrogen generating apparatus the electrolysis cell, an outlet flow means for introducing the for use in motor vehicles to increase the performance of the generated gases into the intake manifold System of an engine of the motor Vehicle. The present invention is also internal combustion engine, a monitoring means for moni directed to components useful in the hydrogen generating toring the operating conditions of the hydrogen generating apparatuS. System and the internal combustion engine, and a control

means connected to the monitoring means for controlling the

BACKGROUND OF THE INVENTION operation of the hydrogen generating System in response to The use of hydrogen as a Supplemental fuel in motor the monitoring means.

vehicle engines has been proposed to increase the perfor In an aspect of the invention there is provided a controller mance of the engine. Hydrogen and oxygen, when used as for controlling a hydrogen generating System for use in an part of the air/fuel mixture for the operation of the engine, internal combustion engine for increasing the efficiency of have been found to increase the performance of the engine the engine and decreasing emissions from the engine. The by increasing the mileage and by reducing the amount of controller comprises at least one interface means for receiv emissions from the engine. The hydrogen and oxygen may ing information on the operating conditions of the hydrogen be generated through electrolysis of an aqueous Solution generating System or the internal combustion engine; at least with the gases given off being mixed with the charge of fuel 25 one control means for controlling a parameter of the hydro and air Supplied to the engine. gen generating System; and a logic circuit connected to the The generation of Small quantities of hydrogen and oxy interface means and control means for providing instructions gen using an electrolysis cell with the hydrogen and oxygen to the control means in response to the information received generated then being combined with the usual air/fuel mix from the interface means.

ture to improve the efficiency of internal combustion engines has been proposed in a number of prior patents. Some BRIEF DESCRIPTION OF THE DRAWINGS Systems of these prior patents utilized the alternator or an Preferred embodiments of the present invention are illus auxiliary generator attached to the engine to provide the trated in the attached drawings in which: electrical power for the System. FIG. 1 is a perspective view of a preferred embodiment of One example of Such a system is shown in U.S. Pat. No. 35 the hydrogen generating System of the present invention; 4,271,793. This patent describes an internal combustion FIG. 2 is a top plan view of a gas generator box of the engine having a fuel System for feeding an air/fuel mixture hydrogen generating System of the present invention; to the combustion chamber and an electrical generation

System, Such as an alternator. An electrolysis cell was FIG. 3 is a block diagram of the electronic process attached adjacent to the engine to generate hydrogen and 40 controller of the hydrogen generating System of FIG. 1; oxygen upon the application of a Voltage between the FIG. 4 is a flow chart of the operation of the electronic cathode and the anode of the electrolysis cell. A gas feed process controller of FIG. 3.

connected the cell to the engine fuel System for feeding the DETAILED DESCRIPTION OF THE hydrogen and oxygen to the engine combustion chambers. PREFERRED EMBODIMENT The electrolysis cell was placed under a predetermined 45 pressure to prevent the electrolyte from boiling off. The cell A preferred embodiment of a hydrogen generating System also included a cooling System and other Safety features. of the present invention is illustrated in FIG. 1. The hydro Another electrolysis cell is disclosed in U.S. Pat. No. gen generating System includes one or more electrolysis 5,231,954. The electrolysis cell of this patent was used for cells 10 which are used to generate the hydrogen and oxygen generating hydrogen and oxygen gases which were added to 50 gases by electrolysis of a Suitable aqueous medium. In the the fuel delivery System as a Supplement to the gasoline or embodiment illustrated in FIG. 1, four such electrolysis cells other hydrocarbons burned therein. The cell was designed to 10 are utilized, however other numbers of cells are possible. reduce the hazard of explosion by withdrawing the gases The number of cells 10 utilized in the system depends upon through a connection with the vacuum line of the positive the capacity of the cell 10 for generating hydrogen and the crankcase ventilation (PCV) system of the engine and by 55 requirements of the engine to which the System is attached. utilizing a slip-fitted top cap for the electrolysis cell. Thus for passenger cars and light duty trucks utilizing A further example of an electrolysis cell for use in gasoline engines, one or two cells 10 each having a capacity connection with an internal combustion engine, for gener up to about 500 cm of hydrogen per minute would be ating hydrogen and oxygen gases is shown in U.S. Pat. No. utilized. For heavy duty trucks and other heavy equipment, 5,458,095. This system utilized an electric pump to draw the 60 especially those utilizing diesel engines, four, Six or eight hydrogen and oxygen gases out of the cell, where the outlet cells 10 each having a capacity up to about 1000 cm of Side of the pump was connected to the air intake manifold hydrogen per minute are preferred.

using a hose having a terminating insert. The insert was The gases generated by the electrolysis cells 10 are fed formed from copper tubing bent at an appropriate angle to through a moisture collector 12 which is connected to the insure that the hydrogen and oxygen gas outlet from the 65 cell 10 by a suitable tubing 14. The output of the moisture pump was in the Same direction as the downstream airflow collector 12 is connected to a gas scrubber 18 by means of in the air intake manifold. a suitable tubing 20 which is provided with a check valve 22

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to prevent back flow of fluids. From the gas scrubber 18 the which is present in an operating engine. Preferably, for gases flow through tubing 24 to an automatic Safety shut-off gasoline engines, a vacuum Safety Switch 48 is utilized to collector 26 which has a ball float valve which shuts off the insure that the engine is running, while for diesel engines, flow of gas if the liquid level in the shut-off collector 26 rises the Sensor is preferably an oil preSSure Switch. The vacuum to the top of the collector 26. safety Switch 48 monitors the vacuum, preferably from a The output of the shut-off collector 26 is connected While different Source than the vacuum intake line to the engine. through tubing 30 to a low flow vacuum pump 32 which the preferred there are numerous Sources of vacuum on the engine, pumps the gases to a Suitable part of the intake System of the heater vacuumSource line.

for monitoring of engine Vacuum is the

The vacuum safety switch 48 is adjusted engine and is adjustable to regulate the flow of the gases. Such that should the level of engine vacuum drop below a The gases may be injected by the pump 32 into the intake preset level, the safety Switch

System of the engine before the carburetor or injector by electronic process controller 40 to48shut will interact with the down the hydrogen connecting the tubing 34 on the outlet of the pump 32 to the generating System.

air breather box of the intake System of the engine upstream from the air filter. Alternatively the gases may be injected firstTherelay hydrogen generating System is also provided with a or Solenoid 54 which is operated by the various

directly into the carburetor or other fuel delivery system of Switches, Such the intake System of the engine or may be injected into the vacuum safetyasswitch the dash module 42, oil pressure Switch or intake manifold of the intake System after the carburetor or provide for the activation48and and hood trunk switch 46 to fuel delivery System if a proper filtering System is provided. electronic process controller 40deactivation of power to the and in turn the electrolysis

AS illustrated in FIG. 1 the hydrogen generating System of cell 10 and Vacuum pump 32 of the hydrogen generating the present invention includes Suitable control and monitor system. In a preferred embodiment the relay 54 may be ing means provided in the preferred embodiment by an incorporated into the electronic process controller 40 as electronic process controller 40. The controller 40 provides described in detail below.

for control of the operation of the hydrogen generating The hydrogen generating System preferably also provides System to provide for maximizing efficiency under all con 25 for visual feedback to the operator of the motor vehicle. The ditions of operation of the engine as well as monitoring the dash module 42 may be provided with one or more LED System to provide for Safe operation. For example, one displays 50, for example one LED display indicating when parameter of operation of the hydrogen generating System which is preferably monitored by the controller is the level the power is turned on to the System, and a Second LED of electrolyte solution in the electrolysis cells 10. As example,toif indicate display trouble with the System, Such as for the level of electrolyte in the electrolysis cell 10 described in detail below, the electrolysis cells 10 are decreases to a level to cause potential problems. Preferably, preferably provided with a level sensor which provides the system is provided with a display module which would feedback to the controller 40 on the level of electrolyte include a alphanumeric display, which can display System solution in the electrolysis cell 10. If the level of the messages provided by the electronic proceSS controller 40. electrolyte solution in the electrolysis cell 10 drops to a level For example, as described in detail below, on operation of which would cause enough exposure of the electrodes of the 35 the System after the ignition is turned on, the electronic cell, the cell could be damaged or production of gases process controller 40 could perform a System Scan for proper becomes inefficient. In this situation, the controller 40 will operation of the components of the System and display shutdown operation of the hydrogen generating System. various messages on the alphanumeric display. Other parameters of the hydrogen generating System con 40 The hydrogen generating System of the present invention trolled by the controller 40 will be explained in detail below. has a number of Safety features built in. AS noted above, one The hydrogen generating System is also provided with a such feature is the detection of the level of electrolyte in the dash module 42 which is mounted in the motor vehicle in a electrolysis cell 10. If the level of the electrolyte is below a location easily accessible by the operator of the motor Specified limit, then a warning would be displayed to advise vehicle. The dash module 42 allows the operator of the 45 the operator to add fluid, preferably Steam distilled water, to motor vehicle to control and monitor the hydrogen gener the cell 10. If the fluid is not added and the level is not ating System as required or desired. The dash module 42 is brought up above the limit within a set period of time, the connected to the ignition of the motor vehicle with a Suitably electronic process controller 40 would shut the system down sized fuse 44. and indicate the System failure. To provide an indication of For Safety reasons, the hydrogen generating System is also 50 the length of time the System is operating, an hour meter 52 provided with one or more safety shutoff Switches 46 which is connected to the electrolysis cells 10, to monitor the will shutdown the System. The engine compartment is operating time of the cells 10.

provided with a shutoff switch 46 mounted such that raising Another monitoring routine of the System could be the the hood of the engine compartment will cause the Switch 46 temperature of the electrolyte Solution in the electrolysis cell to open and shutdown the hydrogen generating System. If the 55 10. If the temperature of the fluid in the cell exceeds a certain hydrogen generating System is mounted in the trunk com limit, boiling of the electrolyte Solution may occur or the cell partment a second shutoff Switch 46 would also be located may be damaged. The Safety temperature limit is Set accord there Such that raising the hood of the trunk compartment ing to many factors, Such as, cell design and capacity, will shut off operation of the system. expected operating conditions and the nature of the electro The hydrogen generating System of the present invention 60 lyte solution. Preferably with the design of the preferred also includes a means of determining that the engine is embodiment described below, the temperature of the elec running so that if power is applied to the controller 40 but trolyte in the electrolysis cell 10 should not exceed 160 F. the engine is not actually running, no electrolysis will take In order to monitor the temperature in the cell, a temperature place. The means to determine that the engine is running probe may be provided to provide a feedback on the elec could be a Sensor monitoring one or more of the engine 65 trolyte Solution temperature. If the temperature increases conditions when the engine is operating. For example, a above a preselected Set point, the electronic process con Sensor could be used to monitor vacuum or oil pressure troller 40 could limit the current to the cell 10 to reduce the

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S 6 amount of electrolysis taking place, and thereby reduce the bly is placed within the case the adapters are in alignment temperature of the cell 10. Should the temperature not with terminal 70.

reduce or continue to rise above the Set point, the electronic The electrode assembly provides for a monocell monopo process controller 40 could shut down the electrolysis cell lar electrode assembly for increased efficiency of the elec 10 by disrupting the power being provided to the cell 10 and trolysis reaction in the electrolysis cell 10. The materials restore functioning of the System once the appropriate from which the electrode assembly is constructed are temperature is attained. Selected to minimize the effects of different coefficients of The hydrogen generating System of the present invention expansionof the of the materials, withstand Strong corrosive action electrolyte solution and provide effective and efficient also monitors the engine operation through the oil pressure electrolysis process. Thus, preferably, the electrode plates or vacuum safety switch 48, as described above. If the are a Suitable StainleSS Steel material, most preferably nickel engine vacuum or oil pressure drops below a preset level, plated Stainless Steel.

then the electronic process controller 40 will shut down the The electrolyte solution utilized within the electrolysis System. In addition, as the preferred embodiment of the cell 10, is preferably a basic aqueous Solution to provide for present invention utilizes the vacuum pump 32, the proceSS increased efficiency of the electrolysis reaction. Preferably, controller 40 could also monitor the operation of the vacuum 15 the Solution is also adjusted to remain in Solution form and pump 32, particularly with respect to the electrical power not freeze at extremely low temperatures, down to -40 or being provided to the pump 32. Should the electric circuit to more. Most preferably, the electrolyte solution is a 20 to the pump 32 be interrupted, then the electronic proceSS 30% KOH solution. The solution within the gas scrubber 18 controller 40 will shut down the system by stopping the is preferably a Silicate free Solution with a Viscosity to allow electrical power supplied to the electrolysis cell 10. In the bubbles to break to the Surface quickly and not accu addition, should the gas Supply line of the gases generated mulate within the Solution.

by the electrolysis cell 10 become blocked such that the preSSure in the line increases, then the electronic proceSS thatIt the is preferred for ease of installation and increased Safety hydrogen generating System of the present invention controller 40 will sense that through the pump circuit and be provided as a modular apparatus as illustrated in FIG. 2. shut down the power supplied to the electrolysis cell 10. 25

In this preferred embodiment, the System includes a gas

When the electronic process controller 40 shuts down the generator box which contains the electrolysis cells, the operation of the electrolysis cells, it is preferred if the power Source, and a block of Sensors to monitor operation of residual energy stored in the cells 10 be removed. This is the electrolysis process. The intelligent electronic proceSS preferably accomplished by a Second relay 56 in conjunction controller, a pump module, and a block of Sensors mounted with a capacitor 58 and resistor 60. When the power to the on the vehicle/chassis are provided as Separate modules. The electrolysis cell is removed by the electronic process box is provided with a closable and lockable lid and is also controller, the relay 56 is activated and connects the cells to provided with a safety switch which shuts down the system ground to bleed off any residual energy stored in the cells 10. if the lid is opened.

The electrolysis cell 10 utilized in the hydrogen generat 35 By adopting a modular Structure for the hydrogen gener ing System of the present invention is preferably the cell ating System, installation of the System is simplified as the described in detail in PCT Application No. CA99/00590, gas generator may be easily installed and connected to the filed Jun. 29, 1999, the disclosure of which is hereby other components. By providing the gas generator in its own incorporated by reference. Electrolysis cell 10, preferably box, the electrolysis cells may be shielded for potential has a cylindrical shaped case 62, constructed of a Suitable 40 damage from impact in the event that the vehicle is involved material which would be inert to the electrolyte solution and in an accident. The use of the gas generator box also allows would not be affected by the Voltages or temperatures for ease in varying the number and size of electrolysis cells encountered in the electrolysis cell 10. The case 62 should to match the requirements Specific to every individual appli also preferably have a co-efficient of expansion which does cation. The size and total number of cells installed in the gas not cause significant expansion of the dimensions of the cell 45 generator box defines maximum capacity of hydrogen/ 10 under the operating conditions of the hydrogen generat oxygen rates and this is a function of engine Size and its ing system. Preferably, the case 62 of the electrolysis cell 10 operating parameters. For Smaller engines the System is is a polyvinyl chloride. provided with only one cell, larger engines may demand a The electrolysis cell 10 is provided with a cap 64 which multitude of Such cells connected in Series, allowing opera is welded to the sidewall once the components of the 50 tion at lower current values.

electrolysis cell have been assembled. The cap 64 is pro The gas generator box also includes a controlled, regul vided with an outlet 66 to which the tubing 14 is connected. lated power supply preferably a DC-DC power converter Cap 64 is also provided with a fill plug 68 which is working in current limit with a logic interface is the main removable to allow the addition of distilled water or elec component of this device. This power Supply is capable of trolyte solution to the cell as the level of fluid in the 55 varying the current output to a profile Supplied by the electrolysis cell 10 decreases. Preferably, the fill plug 68 also intelligent process controller, which will result in optimum incorporates a pressure release mechanism to provide for hydrogen and oxygen quantities being produced and then relief of the pressure within the cell 10 should the interior delivered to the engine. This allows output of system to be preSSure increase beyond a Set limit. adjusted to optimum profiles, according to the demand. The electrolysis cell 10 is provided with an electrode 60 A set of Sensors is installed in the gas generator box to assembly which is described in detail in PCT Application monitor operation of the hydrogen generating System as No. CA99/00590. The electrodes that make up the electrode described above. Such Sensors monitor one or more of assembly are provided as a monocell monopolar assembly of temperature, vacuum, Voltage current, temperature and pH. an anode and a cathode. The outside cathode and anode The information is Sent via an appropriate wiring harneSS to electrode plates are provided with an adapter for electrical 65 the electronic proceSS controller. connection to the positive and negative Supply from the An automatic filler may also be provided to Supply the motor vehicle electrical system. When the electrode assem necessary water to the electrolysis cells in order to increase

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the autonomy of operation of this System. The operation of present from the Sensor or Switch or the interface may this filler is controlled by the electronic process controller in provide an indication of the Signal level from the Sensor or response to the level Sensor and is preferably provided with Switch.

a means of heating the water during the winter. For example, for Sensors which provide a digital output, The hydrogen generating System of the present invention Such as a TTL level sensor used as a fluid level sensor in the is commanded, monitored and controlled by the electronic electrolysis cell 10, the output of the sensor could be directly proceSS controller. This device consists of at least the connected to the logic circuitry. The Signal could be con following parts: verted into a “0” or “1” logic signal. The level of the fluid an internal power module which Supplies power to the inside the electrolysis cell is then considered to be “full” or internal circuits of the electronic proceSS controller and to “not full”. When a “not full signal is present, the logic the Sensors, and circuit will extrapolate the results to estimate the actual level a logic module including interfaces, a microcontroller and of electrolyte inside the cell as described below. Volatile or non-volatile memory. Other Sensors may provide a variable output depending The interfaces are one or more interfaces to interface the 15 upon the conditions being monitored Such as a temperature Sensor

Sensors to the electronic process controller. The interfaces temperature whose output varies in direct proportion to the may include A/D converters to convert analog Signals to preferably anSensed. In these circumstances, the interface is analog/digital converter which converts the digital signals, a multiplexer to expand the number of channels that can be monitored and an engine Scanner/ level of the Signal from the Sensor to a digital word which computer engine interface to allow the electronic proceSS may them be processed by the logic circuitry 100. The controller to read the engine's operating parameters (rpms, non-volatile memory would include digital words corre Speed, mass air flow, throttle position, etc.) and read and various Sensors to enable thelevels sponding to predetermined for the Signals from the write into engine's computer (injector's pulse width, valve the Signal is within acceptable rangescircuitry logic to determine if and hence whether the timing, ignition timing, etc.). component of the hydrogen generating System is operating The volatile or static memory includes an EPROM storing 25 within an acceptable range.

the Software Subroutines for the microcontroller. The micro controller reads all the information and defines the output regulate The controller 40 is also provided with a power circuit to profile for the power source. This controller can work in both the electrical power provided to the electrolysis cell. open/closed loops, Various output profiles for the power The controller 40 is connected to the electrical system of the Source can be stored in the EPROM and in this case the motor Vehicle to provide a Source of electrical power for electronic process controller matches these profiles to the operation of the hydrogen generating System. A voltage instant Signal Set received. The electronic process controller allow the logicis circuit

Sensing block connected to the electrical power input to to measure and possibly compare may also have a “Smart” regime similar to the devices that Voltage drops. The power circuit has an output to provide use artificial intelligence. In this case the electronic proceSS electrical power to the electrolysis cell at the proper level, controller changes the output to the power Supply in a 35

Sequential manner reading the Signal Set and adjusting for the level of electrical power being under the control of the optimal efficiency. Using this self-governing mode is rec logic circuitry which interfaces with the power circuit. The amount of power Supplied to the electrolysis cell controls the ommended mainly because the electronic process controller electrolysis can actually determine the best output profile Specific to reaction. AS the amount of power being Supplied every particular engine and duty cycle. 40 is controlled by the controller, the controller can regulate the electrolysis

The electronic proceSS controller may also be provided including engine demand. reaction in response to monitored conditions with the following optional components:

a data-logger to assist the microcontroller in monitoring power The controller may optionally be provided with variable performance of the hydrogen generating System and the 45 regulateregulator the for the pump to enable the logic circuitry to electrical power provided to the pump, and engine/vehicle, hence the flow rate of the pump, if a pump is included as part a display module (preferably as part of the dash module) of the System. In addition in those Systems which utilize a to provide a text or graphical interface displaying perfor variable flow control valve, the controller may be able to mance data and troubleshooting information related to control the flow setting of the valve by means of an interface operation of the engine, and of the hydrogen generating 50 between the logic circuitry and the flow control valve. System, and Another option available would be in those systems in which a downloading interface to allow data transfer from the the output gases of the electrolysis cell are separated before electronic proceSS controller's memory to conventional or introduction into the intake system of the motor vehicle. In Specialized computers. those Situations, the amount of one or both of the gases in the A preferred embodiment of the controller 40 of the 55 mixture being provided to the engine could be regulated. present invention is illustrated in block diagram in FIG. 3. Preferably, the mixture of gasses would be controlled by The controller 40 is provided with a logic circuitry 100 to controlling the amount of oxygen in the mixture. This could control the operation of the controller. Logic circuitry 100 be accomplished by providing an oxygen valve which would includes the programmed instructions for operation of the be controlled by the logic circuitry through an interface to controller preferably stored within a non-volatile memory 60 regulate the amount of oxygen in the mixture. The exceSS which may be part of the logic circuitry 100 or may be oxygen produced by the electrolysis cell could be vented to provided as a separate component of the controller 40. the external environment.

Controller 40 also includes suitable interfaces for interfacing Many later model motor vehicles utilize on-board con the logic circuitry 100 to the sensors and Switches of the trollers or computers to control various parameters of the hydrogen generating System. Depending upon the nature of 65 operation of the engine of the motor vehicle particularly the Sensor or Switch, the interface may be a simple interface with respect to controlling exhaust gas pollution. For to communicate to the logic circuitry that a signal is or is not example, many vehicles are provided with Sensors to deter

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mine the makeup of the exhaust gases or the fuel/air mixture acceptable and proceeds to check the logic circuitry. If the being introduced into the engine. The on-board controller is logic circuitry is not functioning properly, then the controller capable of controlling the fuel/air mixture in response to will cause a message to be displayed and will Stop operation monitored conditions to attempt to minimize as much as of the hydrogen generating System. If the logic circuitry is possible the amount of pollutants in the exhaust gas of the functioning properly, then this will be displayed and the engine. controller proceeds to test the connection with the on-board As illustrated in FIG. 3 the controller 40 of the present emission control module if provided. If the connection is not invention is preferably provided with an interface for the functioning properly, the connection may be retested at on-board controller to receive signals from the on-board preSelected intervals for a preselected period of time. If after controller as well as to provide Signals to the on-board this retesting, the connection cannot be established, a com controller. For example, as the gases being generated by the munication error message is displayed and the System electrolysis cell and introduced into the intake System of the Stopped.

engine would be high in Oxygen content, Such that an Once a Successful connection is established with the on-board controller that was monitoring oxygen content of on-board emission control module, then the Specific param either the fuel/air mixture or the exhaust gas may determine 15 eters Selected for monitoring are Scanned. These parameters that the fuel/air mixture is too lean and may attempt to can include engine rpm, Speed of the vehicle, fuel rate, etc. regulate the mixture to make it richer. In this situation, the The optimum operating conditions of the hydrogen gener controller 40 could provide a signal to the on-board con ating System are then calculated based upon the capacity of troller to tell it that the high oxygen level is from the the System and the values of the operating parameters. The electrolysis reaction and not to adjust the richness of the power output to the electrolysis cells is then adjusted to mixture. The interface between the controller 40 and the achieve the optimum operating condition of the hydrogen on-board controller could also be utilized to monitor engine generating conditions to enable the controller 40 to control the elec System. Based upon the operating parameter, the trolysis reaction depending upon engine conditions and impact indicator,may control module

Such calculate and display a performance as fuel Savings achieved with the demand. Thus under high load conditions, the rate of elec 25 hydrogen generating System.

trolysis could be increased to increase the efficiency of the engine under high demand typical combustion conditions. In The logic circuitry also reads the values continually from idle conditions the combustion would require different the Sensors employed as monitoring means for monitoring hydrogen amounts. the main Safety features or operating parameters of the The controller 40 is also provided with an interface for a hydrogen ating generating System. Such Safety features or oper parameters include the hood open Switch, oil pressure display module which is preferably provided as part of the dash module 42 mounted in the cab of the motor vehicle. or vacuum level Switch, electrolyte level Sensor, etc. If a Display module is as described above capable of displaying positive Signal is received from any of these Sensors or if the at least alphanumeric messages to provide the operator and value from the Sensor is not within the normal operating diagnostic technician of the motor vehicle with an indication 35 range, the System is automatically shut down. of the operation of the System and a warning of any The controller has stored in memory the identification of problems which may arise in the System. The display the various Sensors and includes an indication of the number module may also have the capability of displaying graphical of Such Sensors used in the System. The controller uses a images to graphically display the operation of the System count up or count down function to test the Sensors in and any problem areas. This would be particularly useful 40 Sequence, the controller testing each Sensor in Sequence and with those controllers which include an interface with an then counting up or down until either the number equal to on-board controller used in later models motor vehicles. the total number of Sensors or the counter reaches Zero. The operation of a preferred embodiment of the controller Preferably, the controller uses a count up counter with the of the present invention is illustrated in the flow chart of total number of Sensors Stored in memory. AS illustrated in FIG. 4. On startup the controller resets certain of the 45 FIG. and 4, the controller checks the signal from the first sensor, if the Signal is acceptable, displays the message, incre variables Stored in memory for example by Setting the time to 0 and the variable for the sensor number to 1 and, if ments the counter and test the next Sensor. This is repeated desired, reads values from the non-volatile memory. The until all of the Sensors have been tested and found accept controller then reads the level electrical power available for able. Should any of the Sensors not be functioning properly, the system preferably by reading the level of the input 50 the controller displays the failure message and stops opera voltage to determine if the level of the voltage is sufficient tion of the System.

for proper operation of the system. While the level of voltage It may be preferred that the operation of the electrolysis is the simplest to monitor, other indicators of electrical cells not be started until the system has checked all of the power including current could also be used. If the Voltage operating parameters. It may also be preferred if a positive level is below a preset level, typically about 12 volts, then 55 input from the user is required to Start the electrolysis the controller will display a System failure message Such as operation. In those circumstances, once the controller has the “Low Battery' message shown in the Figure on the tested all of the Sensors, the controller could display a display and Stop operation of the System. If desired, the message to prompt the user to power on the main hydrogen controller could be programmed to recheck the electrical generating System. The controller would then wait until a power level on a preprogrammed interval rather than merely 60 Signal is received indicating that the main power Switch has Stopping the System. This could be useful if the System was been turned on. Alternatively, the controller could automati running on an auxiliary power Source which may have to be cally proceed with power up of the System once the main recharged by the main electrical System of the motor vehicle. operating parameters have passed the functional test or a So long as the electrical power is below the operational level manual override could be instigated by the operator of the a message would be displayed to indicate this. 65 System.

If the level of electrical power available for the system is Once the Signal for main power up is received by the acceptable, then the controller displays that the level is controller, the controller turns on the power Supply and then

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proceeds to monitor the output of the on-board emission draw is not within acceptable range, either being too low, control module and the Sensors employed as monitoring indicating a pump malfunction or too high indicating a pump means to monitor the operating conditions of the hydrogen blockage, then the controller displays a pump failure mes generating System. These Sensors include the level Sensor Sage and stops operation of the System. and temperature Sensor for monitoring the level and tem If all of the components of the System are functioning perature of the Solution in the electrolysis cell and for those properly as indicated by the Signals from the various Sensors Systems using a pump to introduce the gases into the engine provided to the controller, the controller will display a intake System, a pump Sensor. System OK message on the display module. The controller The controller reads the signal from the level sensor to continues to monitor both the Sensors for the main Safety determine the level of solution in the electrolysis cell. If the features as well as the Sensors for the operating parameters level is acceptable, the controller proceeds to read the Signal of the System while the System is in operation. So long as all from the next Sensor monitoring the operating conditions of components are functioning properly, the controller contin the hydrogen generating System. If the level of Solution in ues to display the System OK message. Should the controller the electrolysis cell is below acceptable levels, then the determine that one of the components is not functioning controller will calculate the amount of distilled or de-ionized 15 properly or is not operating within acceptable range, then the water required to be added to the cell to bring the level up relevant problem message is displayed and the controller to within an acceptable range. The calculation is based upon carries out the programmed Steps in accordance with the the shape and overall volume of the electrolysis cell as well problem according to the flow chart shown in FIG. 4. Should as the operating time elapsed since the level initially one of the main Safety Sensors indicate a problem, Such as dropped below the acceptable range. For the preferred the hood open Switch indicating that the hood has been embodiment of the electrolysis cells illustrated in the figure opened, then the controller immediately stops the operation being a cylinder of 4 in. diameter, 9 in. height and containing of the System and displays the relevant trouble message. about 1.41 of electrolyte solution, the formula would be: The electronic proceSS controller described above pro Where t is elapsed time since the logic signal “not full” vides for an intelligent performance enhancement System received 25 having the ability to determine, produce and deliver opti mum quantities of fuel enhancers to the engine. While in the i=i(t) and T=T(t)-current and temperature profile over te(0, Specific embodiment described, the enhancer is hydrogen, t)< Ostst the delivery of other enhancers in the form of gaseous, liquid The controller monitors the time in hours since the level or Solid Substances Such as but not limited to hydrocarbons, initially dropped below the acceptable range and utilizes this alcohols, etc. may also be controlled by the electronic elapsed time in the formula. If the elapsed time is Sufficient process controller of the present invention. to cause the level to decrease to the minimum Safety level The electronic process controller of the present invention based upon the operating conditions of the hydrogen gen is also useful in other gas generating Systems. In one erating System, then the controller will Stop the operation of possible application, the electronic process controller and the System and display a warning message. In order to 35 hydrogen generating System may be used to produce hydro properly monitor the elapsed time when the vehicle is being gen gas for use in hydrocracking of petroleum products. In used for intermittent operation, the elapsed time is prefer these Systems, the controller could monitor the incoming ably Stored in non-volatile memory. feed Stock and the output of the operation and adjust the The controller also monitors the temperature of the solu generation of the hydrogen gas as needed. Other applica tion in the electrolysis cell to maintain the temperature 40 tions of the electronic process controller of the present within an acceptable range. AS noted above, the acceptable invention would be apparent to those skilled in the art. temperature range will vary according to cell design, mate In the preferred embodiment, the present invention rials and nature of electrolyte Solution. The temperature in describes a hydrogen generating System that uses hydrogen the cell should be below 170 F. and preferably below 160° and oxygen gasses to enhance the properties of the fuel F. If the temperature is above 160 F., then the controller 45 obtaining better combustion efficiency resulting in a cleaner reduces the electrical power to the cell to slow down the burn and better fuel economy. The reliability of an engine electrolysis reaction. Preferably the electrical power to the outfitted with Such System will increase considerably, result electrolysis cell is controlled by controlling the current ing in a longer life Span, delivering more power and exhaust applied to the cell. When the temperature is above 160 F., ing fewer pollutants.

the controller reduces the current by a factor of 15% and 50 The hydrogen generating System of the present invention then monitors the temperature to ensure that the temperature provides for a efficient generation of hydrogen and oxygen decreases to acceptable levels. If the temperature has not by electrolysis of water within the electrolysis cell 10. The decreased within a specified time, typically on the order of electrolysis reaction is under the control of the electronic 30 minutes, then the controller reduces the current further process controller 40 to adjust the rate of the reaction in and continues monitoring the temperature. If the tempera 55 response to engine conditions. This may be accomplished by ture has not reduced after a predetermined number of regulating the amount of electrical energy provided to the repetitions or if the temperature ever is above 170 F., the cell 10 to regulate the electrolysis reaction and the amount controller Stops operation of the System and displays a fault of gases being generated from the reaction. In addition, the meSSage. flow control valve 30 may also be an adjustable valve with For those hydrogen generating Systems which employ a 60 the flow rate being controlled by the process controller 40. pump for introduction of the gases into the intake System of The hydrogen generating System of the present invention the engine, the controller also monitors the operation of the may optionally be provided with a separator to Separate the pump. Preferably, the controller monitors the operation of hydrogen and oxygen gases given off in the electrolysis the pump by reading a signal corresponding to the current reaction, if desired. In this way, the amount of the hydrogen draw of the pump. If the current draw is within a range 65 and oxygen gas provided to the engine may be regulated by which indicateS proper operation of the pump, then the the electronic process controller 40 to maximize the perfor controller displays this on the display module. If the current mance of the engine.

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Prototype models of the hydrogen generating System of one or more electrolysis cells for generating hydrogen and the present invention were installed on various vehicles Oxygen gases by electrolysis of an aqueous Solution; including a GMC Suburban, Ford Bronco and Cummins a power converter for providing current limited electrical diesel engine for testing purposes. In all cases there was a power to the electrolysis cell; Significant reduction in carbon monoxide emission levels, an outlet flow means for introducing the generated gases particularly at engine idle, where the levels decreased up tp into the intake manifold System of an internal combus 95%. Decreases in the level of the carbon monoxide emis tion engine;

Sions were observed over the full operating range of the a communication unit for displaying System messages to engine and carbon monoxide emissions at Some of these a uSer, levels were so low they were not able to be detected. 1O monitoring means for monitoring the operating conditions Similarly, hydrocarbon emission levels were also reduced of the hydrogen generating System; significantly with reductions as high as 90% being observed.

The use of the hydrogen generating System of the present control devices for controlling the application of electrical invention also resulted in increased performance of the power to the power converter or the flow rate of engines with engine torque shown to increase by as much as 15 generated gases, and 10% and increases of up to 10% in the horse power output a process controller having an input/output connection to of the engine were also observed. Increases in mileage of up the vehicles emission control unit, an output connection to 17% were also observed. to the power converter, an input/output connection to Although various preferred embodiments of the present the communication unit, an input connection from the invention have been described herein in detail, it will be monitoring means and an output connection to control appreciated by those skilled in the art that variations may be devices, the process controller controlling the operation made thereto without departing from the Spirit of the inven of the power converter and the control devices to tion or the Scope of the appended claims. optimize performance and Safety in response to inputs The embodiments of the invention in which an exclusive from the power converter, the vehicle's emission con property or privilege are claimed are as follows: 25 trol unit, the communication unit and the monitoring 1. A hydrogen generating System for use in an internal CS.

combustion engine for increasing the performance and the 5. The hydrogen generating System of claim 4 wherein the efficiency of the engine and decreasing emissions from the process controller operates in both open and closed loops. engine, the hydrogen generating System comprising: 6. The hydrogen generating System of claim 4 wherein the one or more electrolysis cells for generating hydrogen and process controller operates using artificial intelligence. oxygen gases by electrolysis of an aqueous Solution; 7. The hydrogen generating System of claim 4 wherein the a power Source for providing electrical power to the control devices include a means for varying pump Speed. electrolysis cell; 8. The hydrogen generating System of claim 4 wherein the control devices include relays for cutting power to the power an outlet flow means for delivering and introducing the 35 COnVerter.

generated gases into the intake manifold System of an 9. The hydrogen generating System of claim 4 wherein the internal combustion engine, the outlet flow means process controller monitors engine conditions via the emis including a gas delivery line, a vacuum pump and a Sion control unit and controls the current profile Supplied to shut-off collector, the shut off collector including an the electrolysis cells in response to engine conditions. inlet, an outlet, a receptacle into which liquids can drop 40 10. The hydrogen generating System of claim 4 wherein by gravity from the inlet and a ball contained in the the power converter is a DC-DC converter.

receptacle and capable of floating on the aqueous 11. The hydrogen generating System of claim 4 wherein Solution, the outlet including a valve Seat into which the the monitoring means is Selected from the group consisting ball can Seat to Substantially Seal the outlet against of a Sensor for monitoring gas preSSure in the outlet flow passage of fluids, 45 means, an engine Vacuum Switch, an engine oil preSSure a monitoring means for monitoring the operating condi Sensor, an electrolyte level Sensor or an electrolyte tempera tions of the hydrogen generating System including ture SenSOr.

means for detecting a significant change in the pressure 12. A hydrogen generating System as in claim 1 further or gas in the gas delivery line, and comprising a circuit communicating electrical power from a control means in communication with the monitoring 50 the power Source to the electrolysis cell and a means for means and operable to shut down the electrolysis cells breaking the circuit from the power Source to the electrolysis in response to a Significant change in the pressure of the cells and connecting the electrolysis cells to ground when gas in the gas delivery line as created by the ball Seating power is removed from the electrolysis cells by the control in the valve seat of the shut off collector. CS.

2. The hydrogen generating System of claim 1 wherein the 55 13. A hydrogen generating System as in claim 4 further means for detecting a Significant change in the pressure of comprising a circuit communicating electrical power from the gas is a Sensor reading a signal corresponding to the the power Source to the electrolysis cell and a means for current draw of the pump. breaking the circuit from the power Source to the electrolysis 3. The hydrogen generating System of claim 1 wherein cells and connecting the electrolysis cells to ground when means for detecting a Significant change in the pressure of 60 power is removed from the electrolysis cells by the control gas in the gas delivery line Senses pressure in a portion of the CS.

gas delivery line between the electrolysis cells and the shut 14. A proceSS for controlling a hydrogen generating off valve. System for use in an internal combustion engine of a vehicle, 4. A hydrogen generating System for use in an internal the hydrogen generating System including one or more combustion engine for increasing the performance and the 65 electrolysis cells for generating hydrogen and oxygen gases efficiency of the engine and decreasing emissions from the by electrolysis of an aqueous Solution; a power converter for engine, the hydrogen generating System comprising: regulating electrical power to the electrolysis cell; an outlet

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flow means for introducing the generated gases into the ing operation of the pump to vary the flow of gases in intake manifold System of an internal combustion engine; a response to engine operation.

monitoring means for monitoring the operating conditions of 17. The proceSS for controlling a hydrogen generating the hydrogen generating System, and a control means includ System as defined in claim 14 further comprising outputting ing a microprocessor connected to the monitoring means for a control profile to the emission control unit to vary opera controlling operation of the hydrogen generating System in tion thereof in response to Signals from the monitoring response to the monitoring means, the proceSS comprising: CS.

18. The proceSS for controlling a hydrogen generating receiving input from an emission control unit of the System as defined in claim 14 wherein the inputs are Selected vehicle concerning engine operation; and from the group comprising engine rpm, Speed, mass air flow Supplying a control profile to the power converter to vary or throttle position.

current output to the electrolysis cells to optimize the 19. The proceSS for controlling a hydrogen generating generation of gases in response to engine operation. System as defined in claim 14 further comprising logging 15. The proceSS for controlling a hydrogen generating data from the received inputs for monitoring performance of System as defined in claim 14 further comprising receiving 15 the vehicle.

input from the monitoring means and Supplying at control 20. The proceSS for controlling a hydrogen generating profile to the power converter to vary current output to the System as defined in claim 14 further comprising logging electrolysis cells. data from the control profile for monitoring performance of 16. The proceSS for controlling a hydrogen generating the hydrogen generating System.

system as defined in claim 14 wherein the outlet flow means includes a pump and the process further comprising adjust k k k k k