E-Turbocharger Engine Brake Torque Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Downsized internal combustion engines in commercial vehicles face challenges in providing sufficient engine brake capability, especially at low speeds, due to reduced torque development, which is exacerbated by the limitations of hybrid and electric vehicle solutions that are either costly or invasive in implementation.
Innovation Solution
The integration of an e-turbocharger paired with a BRM machine, where the e-turbocharger boosts engine pressure through a compressor and turbine connected to an electric motor-generator, and the BRM generates maximum electric energy for braking, allowing efficient engine brake operation even with a BRM developing less than 1/5 of the main engine's power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If downsized internal combustion engines are used, then fuel efficiency and emissions are improved, but engine brake capability at low speed deteriorates
Solution Approach 1:
The patent combines a downsized internal combustion engine with an electric motor-generator unit (e-turbocharger) to create a hybrid system. The electric motor compensates for the reduced brake capability of the downsized engine at low speeds, while the engine provides efficient cruising performance. This merging allows the system to achieve both fuel efficiency and sufficient engine brake capability.
Solution Approach 2:
The electric motor-generator acts as an intermediary between the downsized engine and the vehicle braking system. During engine brake procedures, the electric motor provides additional torque to compensate for the engine's insufficient brake capability at low speeds, enabling the downsized engine to effectively brake the vehicle without requiring a larger displacement engine.
2Reliability
If hybrid propulsion is implemented, then engine brake capability is improved, but device complexity and implementation difficulty increase
Solution Approach 1:
The electric motor-generator unit serves multiple functions: it acts as a compressor during engine operation, provides brake assistance during engine brake procedures, and can function as a starter motor. This multi-functionality reduces the need for separate dedicated components for each function, thereby limiting the increase in device complexity while improving engine brake capability.
3Power
If high-power batteries are used, then electric drive capability is improved, but weight and cost increase
Solution Approach 1:
Instead of equipping the vehicle with a high-power battery system capable of providing full engine power (200 kW), the patent uses a partial action approach where a smaller battery (50 kW) provides sufficient assistance during critical operations like engine brake procedures and frequent starts. This partial capability is adequate for the specific application requirements, avoiding the excessive weight and cost of a full-power battery system.
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 enables effective engine braking in downsized engines by increasing air mass and energy dissipation, storing energy in a battery pack, and providing sufficient torque without the need for high-power electric motors and batteries, thus optimizing engine performance in commercial vehicles with reduced power capacity.
Implementation Method 1
a turbine operatively arranged on the exhaust line of the same internal combustion engine
Implementation Method 2
a compressor operatively arranged on the inlet line of the internal combustion engine
Implementation Method 3
the BRM is controlled as generator to produce the maximum electric energy
Data Source
Figure 1
AI summary
Method for improving an engine brake procedure, in particular for a combustion engine installed in a commercial or industrial vehicle, the method including the preliminary steps of providing the internal combustion engine (E) of a e-turbocharger (E-TCU) and a second motor-generator (EMU) operatively coupled with a crankshaft (CK) of the internal combustion engine; the method including the following steps when an engine brake operation is active: controlling said first electric motor-generator (EM) to increase the boost produced by said compressor, and controlling said second motor-generator (EMU) to apply its maximum possible braking torque to the combustion engine.