Modular Rankine Power System for Exhaust Heat Recovery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing systems for recovering energy from exhaust gases in internal combustion engines are bulky, complex, expensive, inefficient, and difficult to integrate and maintain, leading to inefficiencies in converting waste heat into usable energy.
Innovation Solution
A modular Rankine power system comprising an aftertreatment assembly, an evaporator assembly, and a power pack, where the aftertreatment assembly includes an exhaust conduit for receiving exhaust gases, and the evaporator assembly is in thermal communication with the exhaust conduit to convert waste heat into mechanical and electrical energy using a working fluid loop, allowing for easy installation, service, and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If known energy recovery systems are implemented, then waste heat conversion capability is improved, but device complexity and bulk increase
Solution Approach 1:
The system is divided into three separate modular assemblies: aftertreatment assembly, evaporator assembly, and power pack. Each assembly can be independently manufactured, installed, and maintained, reducing overall system complexity while maintaining waste heat conversion functionality.
Solution Approach 2:
The aftertreatment assembly serves dual purposes: it treats exhaust gases (original function) and simultaneously provides thermal energy to the evaporator for power generation (additional function), eliminating the need for separate energy recovery equipment.
2Loss of energy
If known energy recovery systems are implemented, then waste heat conversion capability is improved, but ease of installation and maintenance deteriorates
Solution Approach 1:
The modular assembly design allows each component to be independently installed and maintained. The power pack can be serviced without removing the aftertreatment or evaporator assemblies, significantly improving ease of installation and maintenance.
Solution Approach 2:
The evaporator assembly acts as an intermediary component that can be positioned between the aftertreatment assembly and power pack, allowing for flexible installation configurations and easier access to individual components for maintenance.
3Loss of energy
If known energy recovery systems are implemented, then waste heat conversion capability is improved, but cost increases
Solution Approach 1:
The system merges the aftertreatment function with the heat source function, using the existing exhaust treatment infrastructure as the thermal source for power generation. This eliminates the need for separate high-cost energy recovery equipment.
Solution Approach 2:
The aftertreatment assembly performs both exhaust treatment and heat provision functions, maximizing the utility of existing components and reducing the need for additional expensive equipment dedicated solely to energy recovery.
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
The system effectively converts waste heat from exhaust gases into electrical energy, improving efficiency and reducing maintenance complexities, while being easily integratable into existing vehicle systems.
Implementation Method 1
The evaporator assembly is in thermal communication with the exhaust conduit to convert waste heat into mechanical and electrical energy
Implementation Method 2
The evaporator assembly includes a first portion of a working fluid loop
Implementation Method 3
The power pack includes a tank, a condenser, a pump and an expander fluidly connected by a second portion of the working fluid loop
Implementation Method 4
The power pack includes a tank, a condenser, a pump and an expander fluidly connected
Data Source
AI summary
A power system for converting waste heat from exhaust gases of an internal combustion engine to electrical energy includes an aftertreatment assembly positioned within a first housing. The power system also includes an evaporator assembly positioned within a second housing. The evaporator assembly is positioned directly adjacent the aftertreatment assembly. The evaporator assembly includes a first portion of a working fluid loop in thermal communication with a first length of an exhaust conduit that extends from the aftertreatment assembly into the second housing. The power system also includes a power pack positioned inside a third housing. The power pack is positioned directly adjacent the evaporator assembly opposite to the aftertreatment assembly. The power pack includes a tank, a condenser, a pump and an expander fluidly connected by a second portion of the working fluid loop. The second portion is fluidly connected to the first portion of the working fluid loop.