Closed-Cycle Engine Control for Power Density and Load Response

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Solution Overview

Problem

Existing power generation and distribution systems face challenges in achieving improved power generation efficiency, reduced emissions, and increased power density while addressing issues related to sizing, portability, and flexibility in response to changing power demands.

Innovation Solution

A closed cycle engine system with a piston assembly and an electric machine, controlled by a sensor-based control system that adjusts engine operations to optimize power output and efficiency, utilizing a control command to manage the input of engine working fluid.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If closed cycle engine arrangements are used, then improved efficiency over other engine arrangements is achieved, but relatively larger power output or power density is difficult to provide

Engineering Contradiction:
ImproveefficiencyVSAvoidpower output
Core Design Contradiction:
Use of energy by moving objectVSPower

Solution Approach 1:

The system dynamically adjusts the piston movement characteristic (such as stroke length or speed) to optimize the balance between efficiency and power output. The control system modifies operational parameters in real-time based on load conditions, allowing the closed cycle engine to maintain high efficiency while adapting to different power demand levels.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The control system changes key operational parameters including piston movement characteristics and engine working fluid input to optimize performance. By adjusting these parameters, the system can shift between efficiency-optimized and power-optimized operating modes, resolving the contradiction between maintaining high efficiency and providing sufficient power output.

Inventive Principle:
Principle #35Parameter changes

2Use of energy by moving object

If closed cycle engine arrangements are used, then improved efficiency is achieved, but improved power density is difficult to provide

Engineering Contradiction:
ImproveefficiencyVSAvoidpower density
Core Design Contradiction:
Use of energy by moving objectVSProductivity

Solution Approach 1:

The system employs dynamic control of piston movement characteristics to optimize power density while maintaining efficiency. By adjusting stroke length, speed, and timing based on operational conditions, the engine can achieve higher power output per unit volume without sacrificing the efficiency advantages of closed cycle operation.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The control system enables the closed cycle engine to perform multiple functions optimally - maintaining high efficiency for energy conservation while also providing improved power density for compact applications. The system adapts its operation to serve different performance requirements from the same base design.

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Power

If conventional power generation systems are used, then power output is provided, but transmission losses increase

Engineering Contradiction:
Improvepower outputVSAvoidtransmission losses
Core Design Contradiction:
PowerVSLoss of energy

Solution Approach 1:

The system generates electrical power directly at the point of use through the integrated electric machine, eliminating the need for long-distance power transmission. This self-service approach allows the prime mover to directly drive the electrical generator, providing power locally and avoiding transmission losses entirely.

Inventive Principle:
Principle #25Self-service

4Device complexity

If fixed operational mode is used, then system simplicity is maintained, but flexibility in response to changing power demands is reduced

Engineering Contradiction:
Improvesystem simplicityVSAvoidflexibility
Core Design Contradiction:
Device complexityVSAdaptability or versatility

Solution Approach 1:

The control system introduces dynamic adjustment capabilities that allow the engine to adapt to changing power demands in real-time. By modifying piston movement characteristics and working fluid input based on load conditions, the system achieves flexibility without requiring multiple fixed-mode engines or complex mechanical reconfiguration mechanisms.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The control system continuously monitors operational parameters and adjusts engine performance accordingly. This feedback mechanism enables the system to respond automatically to changing power demands, maintaining optimal efficiency while providing the flexibility to handle varying load conditions without manual intervention or complex mechanical changes.

Inventive Principle:
Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enhances power generation efficiency, reduces emissions, and improves power density, while providing flexibility in responding to dynamic load changes and power demands.

Implementation Method 1

a piston assembly movable within the piston body... detect a piston movement characteristic of the piston assembly movable within the piston body

Methodology Applied
Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

An electric machine is operatively coupled with the piston assembly... determine a control command based at least in part on data received from the one or more sensors. The control command is selected based at least in part to cause the electric machine operatively coupled with the piston assembly to generate a preselected electrical power output

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP3973166B1Energy conversion apparatus and control system
Publication Date: 2025.07.09 HYLIION HOLDINGS CORP
  • EP3973166B1 patent drawingFigure 1.1.1~1.1.2
  • EP3973166B1 patent drawingFigure 1.1.3
  • EP3973166B1 patent drawingFigure 1.1.4

AI summary

A system including a closed cycle engine having a piston body defining a hot side and a cold side and having a piston assembly movable within the piston body. An electric machine is operatively coupled with the piston assembly. A control system includes one or more sensors operable to detect a piston movement characteristic of the piston assembly movable within the piston body. A controller is communicatively coupled with the one or more sensors and a controllable device. The controller is configured to determine a control command based at least in part on data received from the one or more sensors. The control command is selected based at least in part to cause the electric machine operatively coupled with the piston assembly to generate a preselected electrical power output. The controller provides the determined control command to the controllable device. The controllable device is operable to control an input to an engine working fluid disposed within the piston body.