Supercharged Turbo-Compound Engine with Electric Torque Converter
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Solution Overview
Problem
Existing engine technologies, such as mechanical and electric turbo-compound schemes, face limitations in fuel consumption reduction, power density, transient performance, and exhaust temperature management, leading to inefficiencies and increased material degradation.
Innovation Solution
A supercharged turbo-compound engine apparatus with an inverse two-stage turbocharging scheme, where a low-pressure compressor is driven by a high-pressure turbine, and both turbines are connected on the exhaust pipe, allowing for independent operation and control of high and low-pressure compressors, enabling continuous speed adjustment and optimal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a mechanical turbo-compound scheme is used, then fuel consumption is reduced by 5-10%, but power density is limited to 30-34 kW/l
Solution Approach 1:
The system divides the turbocharging function into two independent stages: a first turbocharger (turbo 1) with turbine 1 and compressor 1 for basic boosting, and a second turbocharger (turbo 2) with turbine 2 and compressor 2 for additional compression. This segmentation allows each stage to operate independently and contribute differently to overall system performance, enabling both fuel efficiency improvements and enhanced power density.
Solution Approach 2:
The patent merges two turbo-compound schemes into a single integrated system where both turbines drive compressors that feed into the same intake system. The first compressor 1 receives fresh air and the second compressor 2 receives compressed air from compressor 1, creating a combined output that delivers both fuel economy benefits and high power density (50 kW/l) simultaneously.
2Power
If a two-stage turbocharged scheme is used, then power density increases to 50 kW/l, but fuel consumption reduction is limited to 0-5%
Solution Approach 1:
The system employs dynamic control through bypass lines with controllable valves (bypass 1 with valve 1, bypass 2 with valve 2) that allow flexible routing of exhaust gases. This enables the turbines to operate dynamically across different operating conditions, optimizing both power output and fuel efficiency by adjusting the split of exhaust energy between the two turbine-compressor stages in real-time.
3Loss of energy
If turbines are placed in series on the exhaust line, then energy recovery is improved, but exhaust temperature management becomes difficult
Solution Approach 1:
The exhaust energy recovery is segmented into two separate turbine stages (turbine 1 and turbine 2) that sequentially extract energy from the exhaust stream. This segmentation allows progressive energy extraction while managing temperature reduction in stages, preventing excessive heat buildup and enabling effective heat management throughout the exhaust 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 configuration achieves significant fuel consumption reduction, increased power density, improved transient performance, and reduced exhaust temperatures, while maintaining reliability and cost-effectiveness.
Implementation Method 1
a low pressure compressor (LPC) directly connected to a high pressure turbine (HPT)
Implementation Method 2
a low pressure turbine (LPT) mechanically connected with an electric generator (30) and with the crankshaft (190) of the combustion engine (1)
Implementation Method 3
a first electric motor (32) connected to a crankshaft (190) of the combustion engine (1) in order to provide a supplementary torque and to drive a high pressure compressor (HPC) (5)
Implementation Method 4
a low pressure turbine (LPT) mechanically connected with an electric generator (30)
Data Source
AI summary
The present invention is relative to a engine apparatus comprising a combustion engine, a low pressure compressor connected to a high pressure turbine. The apparatus also comprises a low pressure turbine and a high pressure compressor. The engine apparatus according to the invention comprises an electrical torque converter comprising at least an electric generator connected so as to be driven by said low pressure turbine and a first electric motor connected so as to drive said high pressure compressor. The torque converter also comprises electronic conversion means suitable to convert the electric energy produce by said electric generator and to power supply and control at least said first electric motor.