Upload
others
View
3
Download
0
Embed Size (px)
Citation preview
Electric Turbo Compounding… A Technology Who’s Time Has Come
• Carl T. Vuk
• John Deere Technical Center
OUTLINE • System Architecture • Review of Hardware Elements
• System Analysis • Test Results • Application Recommendations • Conclusions • Future Work • Questions
24 Aug, 2006
Electric Turbo Compounding: • A System That Converts Waste Exhaust Energy
to Shaft Work, using a Turbine, and Couples it Back to the Engine, Electrically
Why Turbo Compounding ? • Today’s Engines Reject 40% of the Fuel’s Energy in the
Exhaust Gas Stream. The Exhaust is an Excellent Source of High Grade Heat, And it’s Free!
• Turbo Compounding Technology is Available and Proven With Mature System Costs in the Order of $50/kW.
• The Technology Provides Power Growth, Improved Fuel Economy, and Reduced Emissions.
24 Aug, 2006
24 Aug, 2006
System Architecture
Turbo Generator
• Converts Exhaust Energy into Shaft Work
• Converts Shaft Work into Electrical Power• Simple Architecture • Very High Efficiency • Known Technology • Cost Effective Design
24 Aug, 2006
Motor Generator
• Generates When Turbo Gen Can Not (Generating Mode) • Couples Turbo Gen Power Back to Engine (Motoring Mode)• Flywheel Mounted for Compact Packaging • Simple Low Cost Machine Using Known Technology • High Efficiency BPM Technology
24 Aug, 2006
Power Electronics
• Controls Turbo Gen Speed and Delivers DC Power• Manages Motor Gen to Regulate BUS Voltage • Very High Efficiency Over Operating Envelope • Cost Effective Components • Liquid Cooled
24 Aug, 2006
Advanced TurboCharger
• High Pressure Turbine • Significantly Upgraded Efficiency • Fixed Geometry Turbine Nozzle Vanes
• Vaned Diffuser (Compressor)
24 Aug, 2006
24 Aug, 2006
Dyno Test Setup Advanced Turbocharger
Power turbine
Generator
Two Stage Architecture
• Independent Control of Turbo Machinery Elements • Modest Pressure Ratios • Interstage After Treatment • Allows for Simple Turbo Machinery • Improved Transient Response
24 Aug, 2006
Electric Coupling • Power Turbine Speed Control Optimization • Efficient Power Recirculation w/o Fluid Coupling
• Packaging Flexibility • Motor Generator Supports Vehicle Electrification
24 Aug, 2006
Variable Geometry Turbines • VG TurboCharger Not Needed to Drive EGR • VG Power Turbine - Option
• Provides Direct Control of Turbo Compounding Output • Increases Part Load & Part Speed Output • Potential Control of Engine Air Flow & Transient Response
• Fixed Geometry Power Turbine – Option • Better Efficiency at Full Load • Reduced System Complexity • Lower Cost
24 Aug, 2006
24 Aug, 2006
Variable Vane Mechanism (Power Turbine)
24 Aug, 2006
Variable Vane Mechanism (Power Turbine)
Motor Generator Optimization • Efficiency Must be High (95%) in Operating Envelope • Packaging is Critical For Common Design and Minimal
Vehicle Disruption • Every Application is Different. Assuming Will Not Produce
Optimal Results
24 Aug, 2006
Engine Test Data (Output Characteristics) TG Power vs. Load and Speed: TG3 w/-20% & -39% NGV, BW VTG, PCU1 - 7Sep05
0 200 400 600 800 1000 1200 1400
Engine Load - Nm
w/ Tier 3 Emissions Injection Timing and EGR Schedules
0
5
10
15
20
25
30
35
40
45
50
55
60
TG P
ower
- kW
e
2300 RPM - TG3 w/-39% NGV - BW VTG 2300 RPM - TG3 w/-20% NGV - BW VTG 2300 RPM - TG3 w/Nom NGV - BW VTG 2100 RPM - TG3 w/-39% NGV - BW VTG 2100 RPM - TG3 w/-20% NGV - BW VTG 2100 RPM - TG3 w/Nom NGV - BW VTG
24 Aug, 2006
Engine Performance Data (Fuel Economy)
Fuel Economy: Combined Engine Shaft + Electric Power Outputs
300 500 700 900 1100 1300
Engine Load - Nm
190
195
200
205
210
215
220
225
230
235
240
245
250
255
260
Com
bine
d SF
C -
g/kW
h
Non-Turbocompound Baseline Engine
Turbocompound Engine
24 Aug, 2006
Application Targets – Turbo Compounding
• High-Duty Cycle Steady State Operation MaximizesBenefit
• High Annual Usage Improves Payback • Vehicle Electrification Helps Justify Added Cost
• Motor/Gen Needed Even w/o TurboCompounding • More Efficient to Use Electrical Power in Vehicle
• Power Growth • Valuable in Some Applications • Allows Smaller Higher Duty Cycle Engines in
Applications Not Needing Power Growth
24 Aug, 2006
24 Aug, 2006
Ideal Applications
Combines
Large Tractors Row Crop Tractors
Trucks
24 Aug, 2006
Tractor Mounted Turbo Generator
24 Aug, 2006
Hardware Integrated in Tractor
24 Aug, 2006
Deere 9L Engine in International Truck
Conclusions: • 20% Power Growth Has Been Demonstrated With Little
Adverse Impact On The Engine. Higher Output is Possible. • Fuel Economy Improvements of 10% Have Been
Demonstrated at Tier 3 Conditions • Turbo Compounding is Compatible With Emissions and
Appears to Provide Benefit • An Electrically Coupled Two Stage Architecture offers
Control, Efficiency, Emissions, and Packaging Benefits. It Also Supports Electrification.
• System Costs Suggest Commercialization Potential
24 Aug, 2006
Future Work • Evaluate Benefits of the Variable Geometry Power Turbine
• Characterize Performance Benefits in Vehicles • Deere Tractor • On-Highway Truck
• Expand Scope to Include Larger Engines • Develop Next Generation Hardware
• Optimize for Tier 4
24 Aug, 2006
Acknowledgements • I would like to thank John Deere, US Department of Energy,
International Truck, and Eaton for support of this program, and for allowing us to share a high level overview of this work.
24 Aug, 2006
24 Aug, 2006
Questions ?