Dual Flywheel Power Transfer Assembly for Engine Load Management
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Solution Overview
Problem
Existing engine power transfer systems face limitations in extending engine life, reducing fuel consumption, and managing load spikes, as they require dedicated electrical power sources and have practical limits on kinetic energy storage in flywheels, leading to increased system costs and complexity.
Innovation Solution
A power transfer assembly comprising a first flywheel coupled to the engine crankshaft, a second high-speed flywheel selectively coupled to the first, and transmission units for transferring mechanical power between the flywheels and engine accessories, with a controller to synchronize and proportionally engage the flywheels based on speed differences, enabling efficient energy transfer and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a dedicated electrical power source is used to drive engine accessories, then the engine can be shut off to extend life and reduce fuel consumption, but the system cost, service/replacement cost, system bulk, and packaging complexity increase
Solution Approach 1:
The patent combines the flywheel energy storage system with the existing engine accessory drive system. The second flywheel is selectively coupled to the first flywheel and engine accessories through transmission units, merging kinetic energy storage with mechanical power transfer to eliminate the need for separate electrical power sources while maintaining accessory operation during engine shutdown
Solution Approach 2:
The flywheel system serves multiple functions: it acts as a kinetic energy storage device, a power transfer mechanism, and an accessory drive system. The selective coupling and transmission units enable the same components to perform different functions depending on operational mode, reducing overall system complexity compared to dedicated electrical systems
2Power
If a single flywheel is used to store kinetic energy for compensating excess load demand, then the engine can handle load spikes, but the packaging space, journal bearing capacity, and resistance to engine starting are limited
Solution Approach 1:
The patent divides the flywheel system into two separate flywheels: a first flywheel coupled to the crankshaft for primary rotational inertia, and a second flywheel selectively coupled for additional kinetic energy storage. This segmentation allows each flywheel to be smaller and lighter than a single large flywheel would need to be, reducing packaging space requirements while maintaining or enhancing load compensation capability
Solution Approach 2:
The system uses selective coupling mechanisms that dynamically engage or disengage the second flywheel based on operational needs. During normal operation, the second flywheel can be disengaged to reduce rotational inertia and ease engine starting. During load spikes, the second flywheel is engaged to provide additional kinetic energy, allowing the system to adapt its power delivery characteristics
3Use of energy by moving object
If the second flywheel is selectively coupled to the first flywheel and engine accessories, then kinetic energy can be efficiently transferred for accessory power, but the transmission units add mechanical complexity
Solution Approach 1:
The transmission units act as intermediary mechanisms between the flywheels and engine accessories, providing controlled power transfer. These intermediaries enable efficient mechanical energy transfer while managing the complexity through standardized coupling mechanisms that can be selectively engaged or disengaged based on operational requirements
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 solution enhances engine efficiency by utilizing stored kinetic energy for accessory power, reducing fuel consumption, and managing load spikes, while minimizing system costs and complexity by leveraging the high-speed flywheel for inertial starting and accessory operation.
Implementation Method 1
a first flywheel coupled to a crankshaft of the engine... a second flywheel selectively coupled to the first flywheel... adapted to selectively transfer mechanical power between the first flywheel and the second flywheel
Data Source
AI summary
A power transfer assembly for an engine is provided. The power transfer assembly includes a first flywheel coupled to a crankshaft of the engine. The power transfer assembly includes a second flywheel selectively coupled to the first flywheel. The power transfer assembly also includes a first transmission unit coupled to the first flywheel and the second flywheel. The first transmission unit is adapted to selectively transfer mechanical power between the first flywheel and the second flywheel. The power transfer assembly further includes a second transmission unit coupled to the first transmission unit, the second flywheel, and an engine accessory. The second transmission unit is adapted to selectively transfer mechanical power between any one of the first transmission unit and the second flywheel, and the engine accessory.