Decoupled Turbine Generator and Electric Compressor for Work Vehicle Power Systems
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Solution Overview
Problem
Conventional power systems in heavy work vehicles face inefficiencies due to the mechanical coupling of turbines and compressors, leading to control issues, reduced boost and torque output at low speeds, and increased fuel consumption, particularly because the compressor's speed is dictated by the turbine's speed, complicating control and efficiency.
Innovation Solution
A power system with decoupled engine air components, where a turbine generator and electric compressor are mechanically separated and connected through an electrical power network, allowing for independent control and operation, enabling on-demand air flow and precise air/fuel ratio management, reducing pumping losses and emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a turbocharger with mechanically coupled turbine and compressor is used, then engine intake airflow is boosted to improve performance, but the compressor speed is dictated by turbine speed, leading to control issues and reduced efficiency
Solution Approach 1:
The patent divides the traditionally coupled turbocharger system into separate components: an exhaust gas-driven turbine generator that produces electrical power, and an electric compressor that is independently controlled by a motor. This segmentation allows each component to be optimized and controlled independently, resolving the contradiction between power generation and control flexibility.
Solution Approach 2:
The patent replaces the mechanical coupling between turbine and compressor with an electrical connection. The turbine drives a generator to produce electricity, which powers an electric motor that drives the compressor. This substitution of mechanical linkage with electrical energy transfer enables independent control of compressor speed while maintaining the exhaust-driven power source.
2Power
If turbine and compressor are mechanically coupled, then they operate in concert to compress intake air, but this leads to reduced boost and torque output at low speeds
Solution Approach 1:
The patent implements dynamic control where the electric compressor can be independently adjusted based on operating conditions. At low speeds, the compressor can be actively controlled to provide adequate boost pressure regardless of turbine speed, while at high speeds the system can optimize for maximum power output. This dynamic, condition-based control resolves the low-speed performance limitation.
3Reliability
If turbine and compressor are mechanically coupled, then the system operates as an integrated unit, but this complicates control and increases fuel consumption
Solution Approach 1:
The patent incorporates control systems that monitor engine operating conditions and adjust the electric compressor accordingly. The system receives feedback from sensors monitoring parameters such as intake pressure, exhaust flow, and engine load, and dynamically adjusts compressor operation to optimize efficiency and minimize fuel consumption while maintaining reliable operation.
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
This configuration enhances control over air flow and emissions, improves fuel efficiency, and provides better torque response and boost performance across varying operating conditions by allowing independent sizing and control of turbine and compressor components.
Implementation Method 1
a turbine generator in communication with the exhaust manifold and configured to be driven by a second portion of the engine exhaust gas from the exhaust manifold to generate electrical power
Implementation Method 2
an electric compressor in fluid communication with the intake manifold and configured to be powered by the electrical power from the at least one battery of the power network and to compress at least a portion of the intake air for the engine
Implementation Method 3
the EGR mixer configured to mix the first portion of the engine exhaust gas with fresh air as the intake air
Implementation Method 4
the EGR mixer coupled to receive a first portion of the engine exhaust gas from the exhaust manifold, the EGR mixer configured to mix the first portion of the engine exhaust gas with fresh air as the intake air
Data Source
AI summary
A power system includes an engine; an exhaust gas recirculation (EGR) system supplying a first portion of the engine exhaust gas from the exhaust manifold to the intake manifold; a turbine generator in communication with the exhaust manifold and configured to be driven by a second portion of the engine exhaust gas from the exhaust manifold to generate electrical power; a power network including at least one battery to store the electrical power generated by the turbine generator; and an electric compressor in fluid communication with the intake manifold and configured to be powered by the electrical power from the at least one battery of the power network and to compress at least a portion of the intake air for the engine.