Sequential Twin-Turbo Exhaust System for Agricultural Engines
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Solution Overview
Problem
Conventional supercharging systems for agricultural vehicles face inefficiencies in both transient response and maximum power conditions, with existing solutions like single turbochargers, variable geometry turbines, and dual-stage systems failing to optimize fuel consumption and component size effectively.
Innovation Solution
Implementing a twin-turbo sequential configuration with two supercharger stages in series, each optimized for specific power conditions, and incorporating a smaller ATS portion between the turbines to reduce size and improve dynamic behavior, while ensuring effective pollutant treatment at both low and high power operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single turbocharger is used, then the system achieves a compromise between transient response and maximum power efficiency, but it cannot optimize performance for both low power transient conditions and high power steady-state conditions simultaneously
Solution Approach 1:
The exhaust system is segmented into two separate paths, each with its own turbine (first turbine for low power conditions, second turbine for high power conditions). The bypass means allow selective routing of exhaust gases to the appropriate turbine based on operating conditions, enabling optimization for both transient and steady-state performance without compromise.
2Speed
If a variable geometry turbocharger (VGT) is used, then transient response is improved, but turbine efficiency rapidly decreases when operating away from the target point, significantly increasing fuel consumption at maximum power
Solution Approach 1:
Instead of using a single VGT that must operate across a wide range of conditions, the system segments the operation into two distinct turbines: a first turbine optimized for low power transient conditions and a second turbine optimized for high power steady-state conditions. This eliminates the efficiency penalty of operating a single turbine away from its optimal point.
3Power
If dual-stage supercharging systems are implemented, then compression is improved, but the inertia of two turbines increases, worsening the transient response
Solution Approach 1:
The system dynamically switches between two turbine configurations using bypass means controlled by a control unit. During transient low-power conditions, exhaust gases are routed to the first turbine with lower inertia for rapid response. During steady-state high-power conditions, gases are routed to the second turbine for optimal compression efficiency. This dynamic routing resolves the contradiction between compression capability and transient response.
4Productivity
If a large turbocharger is used, then maximum power efficiency is improved, but the transient response from low rpm is poor
Solution Approach 1:
The system segments the turbocharging function into two separate turbines: a first turbine with smaller size and lower inertia for rapid transient response at low rpm, and a second turbine with larger size for efficient maximum power operation. The bypass means enable selective engagement of the appropriate turbine based on the operating regime, eliminating the need to compromise between these conflicting requirements in a single turbine design.
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 transient response, reduces turbo lag, optimizes vehicle space, and lowers component costs by using smaller, more efficient turbines and ATS systems, ensuring effective pollutant treatment and continuous regeneration of the DPF without forced regenerations.
Implementation Method 1
a first turbine (T1), upstream of the at least an ATS portion, is optimized with respect to the first operating condition of the internal combustion engine
Implementation Method 2
system for treating exhaust gases (ATS) and supercharging of an internal combustion engine
Implementation Method 3
controlling the bypass means so that in steady-state operating conditions of the internal combustion engine, only one of the supercharger stages is active
Implementation Method 4
at least an ATS portion between the turbine of the first stage and the turbine of the second supercharger stage
Data Source
Figure 1
Figure 2
Figure 2a~2b
AI summary
A system for treating exhaust gases and supercharging of an internal combustion engine (EC), in particular of an agricultural vehicle, the internal combustion engine (CE) comprising an intake line (I) and an exhaust line (E), the system comprising a first supercharger stage (TC1) having a first turbine (T1) arranged on said exhaust line immediately downstream of the internal combustion engine (CE) and related first bypass means (BP1) of the first turbine, a second supercharger stage (TC2) having a second turbine (T2) arranged on said exhaust line downstream of said first turbine (T1) and related second bypass means (BP2) of the second turbine, at least a first exhaust gas treatment stage (ATS1) arranged between said first (T1) and said second turbine (T2), processing means (ECU) configured to bypass said second turbine and maintain said first turbine (T1) operating when the internal combustion engine operates in a first operating condition and vice versa when the internal combustion engine operates in a second operating condition; in which the internal combustion engine supplies less power when it is in said first operating condition if compared to when it is in said second operating condition.