Rotating Fluid Expander Flow Control Assembly
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Solution Overview
Problem
Existing flow-control systems for internal combustion engines, such as throttle bodies with butterfly valves, suffer from efficiency losses during partial throttle conditions and add complexity and cost, making them less viable for automotive applications.
Innovation Solution
A flow-control assembly featuring a fluid conduit with a rotating fluid expander, such as a turbine, and a butterfly valve that can configure to block or allow flow through the conduit and expansion conduit, enabling efficient fluid expansion and energy recovery, with an optional electrical generator for power generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a butterfly valve is used to throttle intake air, then the flow rate can be controlled, but efficiency is lost during partial throttle conditions due to flow losses
Solution Approach 1:
The system segments the flow control into two paths: a main path with a flow control valve for precise throttling and a bypass path with a turbine for energy recovery. This segmentation allows the system to maintain flow control capability while recovering energy that would otherwise be lost, directly addressing the efficiency loss problem during partial throttle conditions
Solution Approach 2:
The invention converts the harmful effect of throttling (energy loss) into a beneficial effect by directing a portion of the throttled flow through a turbine. The turbine extracts energy from the bypass flow, transforming what would be wasted energy into useful work that can power accessories or generate electricity, thereby converting the harm of partial throttling into a benefit
2Loss of energy
If energy recovery systems are added to throttle bodies, then efficiency losses can be reduced, but device complexity and cost increase
Solution Approach 1:
The turbine assembly serves multiple functions: it acts as an energy recovery device, a flow splitter, and a power source for accessories. By integrating these functions into a single component, the system reduces overall complexity compared to having separate systems for each function, while still achieving energy recovery during partial throttle conditions
Solution Approach 2:
The invention merges the flow control valve and turbine into an integrated assembly where the valve body incorporates the turbine housing and flow paths. This merging eliminates the need for separate components and connections, reducing device complexity and packaging space while maintaining the energy recovery function
3Loss of energy
If energy recovery systems are added to throttle bodies, then efficiency losses can be reduced, but cost increases
Solution Approach 1:
The integrated valve-turbine assembly is designed as a single manufacturable unit with unified casting or machining operations. This merging reduces the number of parts that need to be produced, inventoried, and assembled, thereby lowering manufacturing costs despite adding the energy recovery function
4Loss of energy
If a rotating fluid expander is added to the flow control assembly, then energy can be recovered, but packaging space requirements increase
Solution Approach 1:
The turbine is nested within the valve body structure, with the turbine housing formed as an integral part of the valve assembly. The flow paths are arranged so that the turbine occupies the space that would otherwise be required for separate flow control components, achieving energy recovery without significantly increasing the overall packaging volume
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 improves efficiency by recovering energy during partial throttle conditions while maintaining simplicity and reducing complexity and cost, allowing for compact integration in automotive engines.
Implementation Method 1
a rotating fluid expander in the fluid expansion conduit configured to expand the fluid and thereby rotate
Implementation Method 2
The rotating fluid expander may comprise a turbine
Implementation Method 3
the rotating fluid expander may be coupled to an electrical generator
Data Source
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AI summary
A flow-control assembly may include a fluid conduit and a flow-control valve in the fluid conduit. The flow-control assembly may further include a fluid expansion conduit with an inlet defined at least in part by the fluid conduit and configured to selectively receive flow of a fluid from the fluid conduit. The fluid expansion conduit may further include an outlet in fluid communication with the fluid conduit downstream of the flow-control valve. A rotating fluid expander in the fluid expansion conduit may be configured to expand the fluid and thereby rotate and in some embodiments generate electricity. In a first position flow is substantially blocked. In a second position flow is allowed through the fluid expansion conduit. In a third position flow through the fluid conduit is allowed without necessarily passing through the fluid expansion conduit. Related systems and methods are also provided.