EP3902988A2 - An electric turbo system in which efficiency is increased by having compressor and turbine on the separate shafts, and working principle thereof - Google Patents

An electric turbo system in which efficiency is increased by having compressor and turbine on the separate shafts, and working principle thereof

Info

Publication number
EP3902988A2
EP3902988A2 EP19901019.0A EP19901019A EP3902988A2 EP 3902988 A2 EP3902988 A2 EP 3902988A2 EP 19901019 A EP19901019 A EP 19901019A EP 3902988 A2 EP3902988 A2 EP 3902988A2
Authority
EP
European Patent Office
Prior art keywords
turbine
compressor
battery
compressor motor
motor
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP19901019.0A
Other languages
German (de)
French (fr)
Other versions
EP3902988A4 (en
Inventor
Mert Alpaya
Iskender KAYABASI
Varlik KILIC
Seckin OZKURT
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Supsan Motor Supaplari Sanayii Ve Ticaret AS
Original Assignee
Supsan Motor Supaplari Sanayii Ve Ticaret AS
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Supsan Motor Supaplari Sanayii Ve Ticaret AS filed Critical Supsan Motor Supaplari Sanayii Ve Ticaret AS
Publication of EP3902988A2 publication Critical patent/EP3902988A2/en
Publication of EP3902988A4 publication Critical patent/EP3902988A4/en
Pending legal-status Critical Current

Links

Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02BINTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B39/00Component parts, details, or accessories relating to, driven charging or scavenging pumps, not provided for in groups F02B33/00 - F02B37/00
    • F02B39/02Drives of pumps; Varying pump drive gear ratio
    • F02B39/08Non-mechanical drives, e.g. fluid drives having variable gear ratio
    • F02B39/10Non-mechanical drives, e.g. fluid drives having variable gear ratio electric
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02BINTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B37/00Engines characterised by provision of pumps driven at least for part of the time by exhaust
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02BINTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B37/00Engines characterised by provision of pumps driven at least for part of the time by exhaust
    • F02B37/04Engines with exhaust drive and other drive of pumps, e.g. with exhaust-driven pump and mechanically-driven second pump
    • F02B37/10Engines with exhaust drive and other drive of pumps, e.g. with exhaust-driven pump and mechanically-driven second pump at least one pump being alternatively or simultaneously driven by exhaust and other drive, e.g. by pressurised fluid from a reservoir or an engine-driven pump
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/10Internal combustion engine [ICE] based vehicles
    • Y02T10/12Improving ICE efficiencies

Definitions

  • the present invention relates to an electric turbo system which is used to reduce the delay, fuel consumption and emission in the internal combustion engine.
  • the present invention relates to an electric turbo system in which compressor and turbine are located on separate shafts and, compressor is driven (operated) by a separate electric motor instead of turbine in order to eliminate all the disadvantages and limitations caused by the presence of the compressor and the turbine on the same shaft in the conventional electric turbo systems and so, in which system is made more efficient, optimal, scalable and flexible by using a separate motor and generator instead of a single machine operating as a motor-generator and, the working principle therefore.
  • the compressor and the turbine are located on the same shaft and, the compressor is driven by turbine. Since the compressor and turbine are on the same shaft, the selection of the compressor and turbine cannot be done separately and thus, it is not possible to use the system in the most efficient way.
  • the compressor and turbine operate on the same shaft, the compressor operates at the same cycle with the turbine instead of the desired cycle. This causes the pressure of the air delivered to the internal combustion engine to be not fully controlled and the combustion efficiency to be not maintained at the maximum point. Besides, since the combustion process in the internal combustion engine cannot be performed optimally, it is not possible that the energy of the combustion gases transferred to the turbine and therefore the energy produced by the generator are at the maximum level.
  • the presence of the compressor and the turbine on the same shaft brings the need for bearing and consequently lubrication.
  • the lubrication system brings extra cost, maintenance and repair workload to the turbo system although it is critically important in terms of performance and efficiency for turbos operating at very high cycle. Also, if the technical difficulties arising in the bearing and lubrication system cannot be overcome, problems will be occurred in the bearing system and they will be able to make the turbo system inoperable.
  • the operation of the compressor and the turbine on the same shaft causes the size of the compressor, electric machine and turbine to not be selected independent to each other.
  • the necessity of using a compressor suitable for the size of the turbine used in the system causes the air pressure transmitted to the internal combustion engine to be quite limited. While the higher-energy exhaust gases (combustion gases) can be obtained, the lower-energy exhaust gases are obtained due to smaller size compressor which has to be used because of the turbine size, consequently less energy is obtained from the generator.
  • the electric machines which are used in the conventional electric turbo systems and operates bidirectional (two-way) as both motor and generator provides lower efficiency compared to the unidirectional (one-way) machines operating only as motor or generator and, this decreases the efficiency of the system.
  • the document EP2621807B1 mentions about an embodiment where plurality of compressor and of the turbine are located in parallel in separate shafts. However, there, compressors are driven by turbines since the turbine and compressor in each shaft are connected to each other, it is not mentioned about a system and working method for driving the compressor by a separate electric motor.
  • the document DE102014208092A1 mentions about a system including a turbo and additional compressor configuration for internal combustion engines. This additional compressor is operated as a support to the turbo. The compressor in the turbo operates on the same shaft with the turbine. The turbine in the turbo is also connected to a generator and, the battery is charged with the electricity produced in the generator. Mentioned additional compressor operates with the power taken this battery. However, there is not mentioned about a system where the turbine and compressor are separated for sizing and driving the compressor separately from the turbine.
  • Aim of the invention is to present an electric turbo system in which compressor and turbine are located on separate shafts and, compressor is driven (operated) by a separate electric motor instead of turbine in order to eliminate all the disadvantages and limitations caused by the presence of the compressor and the turbine on the same shaft in the conventional electric turbo systems and so, in which system is made more efficient, optimal, scalable and flexible by using a separate motor and generator instead of a single machine operating as a motor-generator and, the working principle therefore.
  • Another aim of the present invention is to enable the compressor to be controlled independent from the turbine. Another aim of the invention is to allow the compressor to operate at the desired cycles (instantaneous optimum cycles for the system or the cycles at which the compressor is most efficient) instead of the turbine cycle by controlling the compressor separately from the turbine thanks to the operation of the compressor and the turbine on the separate shafts.
  • Another aim of the invention is to allow the air pressure transmitted to the internal combustion engine to be maintained at the desired level by controlling the compressor speed independent from the turbine speed.
  • Another aim of the invention is to allow combustion within the cylinders to be occur in maximum efficiency and consequently, to maximize the energy of the exhaust gases delivered to the turbine and the amount of the electrical energy generated by the generator by keeping the air pressure delivered to the internal combustion engine at the desired level.
  • Another object of the invention is to enable the compressor and turbine to be used as controllable brake by creating separately controllable resistors at both the exhaust outlet and the air inlet by controlling of the speeds of the compressor and the turbine separately.
  • Another aim of the invention is to reduce the extra cost, maintenance and repair workload of the lubrication system and the risk of the occurrence of the technical problems by eliminating the bearing and lubrication need of the turbo system thanks to the operation of the compressor and the turbine on the separate shafts.
  • Another aim of the invention is to increase the response rate and efficiency of the system by using separate motor and generator instead of a two-way electric machine operating both generator and electric motor on the same shaft.
  • Another aim of the invention is to allow the compressor to operate at the lower temperatures compared to the conventional systems by allowing the compressor side to be less impacted from the high temperatures on the turbine side and so, to allow to be enable to operate with low-cost materials (e.g. plastic) by allowing greater freedom in the material selection for compressor, thanks to the separation of the compressor and turbine from the same shaft onto the different shafts.
  • low-cost materials e.g. plastic
  • Another aim of the invention is to eliminate the necessity of the system to be in block from (for making the system more flexible) by facilitating the placement of the system by separating the compressor, electric machine and turbine from each other and consequently, to minimize the losses in the gas flow system by reducing the number of twisted connections and sharp turns in this twists which increase losses in the gas flow system, thanks to the elimination of the close positioning.
  • Another aim of the invention is to allow the size of the two components to be independently selected (flexibility in the system design) from each other thanks to the separation of the compressor and turbine from each other.
  • Another aim of the invention to ensure the response rate of compressor and consequently the response rate of the system to be greater than the response rate of the compressor driven by the turbine thanks to the operation of the compressor driven by bidirectional electric machine instead of the turbine and the system therefore.
  • the present invention presents an electric turbo (1) system in which compressor (4) and turbine (9) are located on separate shafts and, compressor (4) is driven (operated) by a compressor motor (3) that is a separate electric motor used instead of turbine (9) in order to eliminate all the disadvantages and limitations caused by the presence of the compressor and the turbine on the same shaft in the conventional electric turbo systems and so, in which system is made more efficient, optimal, scalable and flexible by using a separate motor and generator instead of a single machine operating as a motor-generator and, the working principle therefore.
  • Turbo system which allows more fuel to burn in the engine by sending (compressed) air above atmospheric pressure to the internal combustion engine and thus enables more power to be generated from the engine, is a kind of turbomachine that takes its motion energy from exhaust gas (combustion gas).
  • a conventional turbo is basically composed of a compressor operating on the suction side and a turbine operating on the exhaust side.
  • the compressor and turbine are connected to each other by means of a shaft and are bedded in a bearing body.
  • the exhaust gases hit the turbine propeller and then, rotates the rotor consisting of the turbine propeller, shaft and compressor propeller. With this rotational movement, the compressor propeller increases the pressure and density of the air by sucking and compressing it.
  • the electric turbo concept has been introduced by changing the turbo systems.
  • the electric turbo system comprises an external battery and an electric machine operating with the compressor and turbine.
  • the electric machine which operates bidirectionally both as a motor and generator, is located on the same shaft in connection with compressor and turbine.
  • excess turbine energy is converted into electricity by operation of the electric machine in the turbo as a generator.
  • the generated electricity is stored in the external battery located in the turbo system.
  • the electric machine in the turbo system starts to operate as a motor and increases the rotation speed of the compressor with the power it takes (draws) from the battery.
  • the compressor and the turbine are located on the same shaft and the compressor is driven by the turbine. Since the compressor and the turbine are located on the same shaft, problems occur such as; that the selection of the compressor and turbine cannot be made independently to each other, that the compressor runs at the same cycle with the turbine instead of the desired cycle, therefore the combustion process in the internal combustion engine cannot occur in maximum efficiency and the energy produced by the generator cannot be in the maximum amount, the increasement of maintenance and cost due to the requirement of the bearing and lubrication, the failure of being free for material selection in the compressor side by influencing the compressor side from the high temperature on the turbine side, that the size of the compressor cannot be selected independent from the turbine size, the increasement in the losses in gas flow system with increased number of twists and sharp turns as well as the inability to be flexible in the system design as a result of necessity in the positioning of the turbine, electric machine and compressor in the block form, that the response rate of the compressor driven by the turbine via shaft and consequently the response rate of the system are slow, and as a result it is not
  • the present electric turbo (1) system comprises a controller (2) that decides whether the electric turbo (1) system is operated,
  • a compressor (4) which is operated with the initial energy taken from the turbine generator (10) and/or from battery (11 ) by mentioned compressor motor (3) and so, provides the suction and the pressurization of the air (H) that will be sent to the internal combustion engine (7) cylinders,
  • a turbine in which the combustion gases (YG) formed as a result of combustion in the internal combustion engine (7) cylinders are delivered through exhaust manifold (8), a turbine generator (10) which is located on the same shaft with the turbine rotating with the energy of the combustion gases (YG) and thus, generates electricity (E) by starting to operate with the rotation of the turbine (9),
  • a power converter (13) which, locating between turbine generator (10) outlet and mentioned battery (11) inlet, converts the remaining portion of the electrical (E) energy (after using for operating of the compressor motor (3)) generated by the turbine generator (10) to make it suitable for storage in the battery (11),
  • a seconder power converter (14) which, locating between the battery (11) and compressor motor (3), coverts the energy received from the battery (11) to the suitable form for usage of the compressor motor (3).
  • the compressor (4) and turbine (9) operates on the separate shafts.
  • the energy of the exhaust gases (YG) coming from the internal combustion engine is converted to the electrical energy by the turbine generator (10) connected to the turbine (9).
  • the compressed air (H) required in the cylinders is provided by the compressor (4) driven by a separate compressor motor (3).
  • the electrical (E) energy required to drive the compressor motor (3) is provided by the turbine generator (10).
  • the energy required for driving the compressor motor (3) is provided by the support of the battery (11) as well as the turbine generator (10).
  • the battery (11) is charged with the remaining energy after driving of the compressor motor (3).
  • the number of the turbines (9) can be increased to increase the amount of the electricity (E) and consequently the charge level of the battery (11).
  • the plurality of turbines can be used in different order for different purposes by being connected in parallel to each other while turbines may operate in series (the output of one is connected to the input of the other).
  • the plurality of compressor (4) can be used in series or parallel way for increasing the flow rate and pressure of the air (H) delivered to the cylinders.
  • the operating principle of the present electric turbo (1) is as follows;
  • Compressor motor (3) driven by being controlled by the controller (2) operates the compressor (4) with the initial drive energy received from just battery (1 1) or just turbine generator (10) or both of them depending on the situation.
  • the compressor (4) that starts to operate, absorbs the air (H) from the external environment and increases the pressure of the air (H) that will be delivered to the cylinders.
  • the controller (2) provides separate controls of all the compressors (4).
  • the pressurized air (H) at the compressor (4) outlet is made more intense by cooling it by passing it through the intercooler (5), if the vehicle has an intercooler (5) component. Since the condensing air (H) contains more oxygen per unit volume, the combustion process occurred in the cylinder of the internal combustion engine (7) becomes more efficient.
  • More dense air (H) exiting from the intercooler (5) is sent to the internal combustion engine (7) through the suction manifold (6) and is ensured to be burned in cylinders. After combustion process occurred in the cylinders, the high energy combustion gases (YG) coming to the turbine (9) through the exhaust manifold (8) rotate the turbine (9).
  • the rotating turbine (9) enables the turbine generator (10) connected to the same shaft with it to operate and generate electricity (E).
  • the high energy combustion gas (YG) passing through the exhaust manifold (8) can be delivered to a single turbine (9) or to the plurality of turbines (9) that can be operated in different order.
  • the compressor motor (3) is operated by the electricity (E) generated by the turbine generator (10). After the compressor motor (3) is operated, the remaining electric (E) energy is converted by making it suitable for the battery (1 1) by means of the power converter (13) and is stored in the battery (11). Thus, after the energy stored in the battery (11) is converted to the suitable form for usage of the compressor motor (3) by means of the second power converter (14), as well as providing initial drive energy to the compressor motor (3), it is used together with the turbine generator (10) to operate the compressor motor (3) when the turbine generator (10) alone is not enough to operate the compressor motor (3).
  • the loads and temperatures in the internal combustion engine (7) are tracked by the vehicle electronic control unit (12).
  • the controller (2) controls the operation of the compressor motor (3) by tracking both the charge level of the battery (1 1) via the control connection (KB) data received from the battery (1 1) and the temperature value in the internal combustion engine (7) via the control connection (KB) data received from the vehicle electronic control unit (12).
  • the compressor (4) is driven by the compressor motor (3) which is a separate electric motor.
  • the electric (E) energy required for operating the compressor motor (3) is provided by the turbine generator (10).
  • the turbine generator (10) alone is not enough to operate the compressor motor (3), the energy required for driving the compressor motor (3) is provided by the support of the battery (11) as well as the turbine generator (10).
  • the battery (1 1) is charged with the remaining energy after driving the compressor motor (3).

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Supercharger (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)

Abstract

The present invention presents an electric turbo (1) system in which compressor (4) and turbine (9) are located on separate shafts and, compressor (4) is driven (operated) by a compressor motor (3) that is a separate electric motor used instead of turbine (9) in order to eliminate all the disadvantages and limitations caused by the presence of the compressor and the turbine on the same shaft in the conventional electric turbo systems and so, in which system is made more efficient, optimal, scalable and flexible by using a separate motor and generator instead of a single machine operating as a motor-generator and, the working principle therefore.

Description

AN ELECTRIC TURBO SYSTEM IN WHICH EFFICIENCY IS INCREASED BY HAVING COMPRESSOR AND TURBINE ON THE SEPARATE SHAFTS, AND WORKING PRINCIPLE
THEREOF
Technical Field
The present invention relates to an electric turbo system which is used to reduce the delay, fuel consumption and emission in the internal combustion engine.
More specifically, the present invention relates to an electric turbo system in which compressor and turbine are located on separate shafts and, compressor is driven (operated) by a separate electric motor instead of turbine in order to eliminate all the disadvantages and limitations caused by the presence of the compressor and the turbine on the same shaft in the conventional electric turbo systems and so, in which system is made more efficient, optimal, scalable and flexible by using a separate motor and generator instead of a single machine operating as a motor-generator and, the working principle therefore.
Prior Art
In the conventional electric turbo systems, the compressor and the turbine are located on the same shaft and, the compressor is driven by turbine. Since the compressor and turbine are on the same shaft, the selection of the compressor and turbine cannot be done separately and thus, it is not possible to use the system in the most efficient way.
Since the compressor and turbine operate on the same shaft, the compressor operates at the same cycle with the turbine instead of the desired cycle. This causes the pressure of the air delivered to the internal combustion engine to be not fully controlled and the combustion efficiency to be not maintained at the maximum point. Besides, since the combustion process in the internal combustion engine cannot be performed optimally, it is not possible that the energy of the combustion gases transferred to the turbine and therefore the energy produced by the generator are at the maximum level.
The presence of the compressor and the turbine on the same shaft brings the need for bearing and consequently lubrication. The lubrication system brings extra cost, maintenance and repair workload to the turbo system although it is critically important in terms of performance and efficiency for turbos operating at very high cycle. Also, if the technical difficulties arising in the bearing and lubrication system cannot be overcome, problems will be occurred in the bearing system and they will be able to make the turbo system inoperable.
The operation of the compressor and the turbine on the same shaft causes the high temperature on the turbine side to be transmitted to the compressor side and causes the compressor to heat up. This causes that it is not completely free to choose the material for the compressor side, although not as much as on the turbine side.
The operation of the compressor and the turbine on the same shaft causes the size of the compressor, electric machine and turbine to not be selected independent to each other. The necessity of using a compressor suitable for the size of the turbine used in the system causes the air pressure transmitted to the internal combustion engine to be quite limited. While the higher-energy exhaust gases (combustion gases) can be obtained, the lower-energy exhaust gases are obtained due to smaller size compressor which has to be used because of the turbine size, consequently less energy is obtained from the generator.
Since the operation of the compressor, electric machine and turbine on the same shaft requires the system to be in the block form, it is not possible to be flexible and free concerning the placement of the system on the vehicle.
Besides, the electric machines which are used in the conventional electric turbo systems and operates bidirectional (two-way) as both motor and generator provides lower efficiency compared to the unidirectional (one-way) machines operating only as motor or generator and, this decreases the efficiency of the system.
This situation caused to occur the need for an electric turbo system that allows the compressor and the turbine to operate on the separate shafts for allowing the compressor to be independent from the turbine and that provides to increase the overall efficiency of the system by using unidirectional machines that operate only as motor and generator instead of bidirectional electric machines and, the need for working principle therefore.
The document EP2621807B1 mentions about an embodiment where plurality of compressor and of the turbine are located in parallel in separate shafts. However, there, compressors are driven by turbines since the turbine and compressor in each shaft are connected to each other, it is not mentioned about a system and working method for driving the compressor by a separate electric motor. The document DE102014208092A1 mentions about a system including a turbo and additional compressor configuration for internal combustion engines. This additional compressor is operated as a support to the turbo. The compressor in the turbo operates on the same shaft with the turbine. The turbine in the turbo is also connected to a generator and, the battery is charged with the electricity produced in the generator. Mentioned additional compressor operates with the power taken this battery. However, there is not mentioned about a system where the turbine and compressor are separated for sizing and driving the compressor separately from the turbine.
The document US2010213709A1 mentions about an embodiment where the turbine and compressor locate on the same shaft and the compressor is driven by the turbine. In addition, extra power is given to the compressor thanks to that the generator connected to the turbine operates also as motor. However, there is not mentioned about a system and method, wherein the compressor and the turbine locate on separate shafts and which includes motor and generator separately instead of two- way (bidirectional) machine working as motor-generator (electric machine)
As a result, the need for an electric turbo system in which compressor and turbine are located on separate shafts and, compressor is driven (operated) by a separate electric motor instead of turbine in order to eliminate all the disadvantages and limitations caused by the presence of the compressor and the turbine on the same shaft in the conventional electric turbo systems and so, in which system is made more efficient, optimal, scalable and flexible by using a separate motor and generator instead of a single machine operating as a motor-generator and, the working principle therefore, requires the present innovative solution to occur.
Objectives and Short Description of the Invention
Aim of the invention is to present an electric turbo system in which compressor and turbine are located on separate shafts and, compressor is driven (operated) by a separate electric motor instead of turbine in order to eliminate all the disadvantages and limitations caused by the presence of the compressor and the turbine on the same shaft in the conventional electric turbo systems and so, in which system is made more efficient, optimal, scalable and flexible by using a separate motor and generator instead of a single machine operating as a motor-generator and, the working principle therefore.
Another aim of the present invention is to enable the compressor to be controlled independent from the turbine. Another aim of the invention is to allow the compressor to operate at the desired cycles (instantaneous optimum cycles for the system or the cycles at which the compressor is most efficient) instead of the turbine cycle by controlling the compressor separately from the turbine thanks to the operation of the compressor and the turbine on the separate shafts.
Another aim of the invention is to allow the air pressure transmitted to the internal combustion engine to be maintained at the desired level by controlling the compressor speed independent from the turbine speed.
Another aim of the invention is to allow combustion within the cylinders to be occur in maximum efficiency and consequently, to maximize the energy of the exhaust gases delivered to the turbine and the amount of the electrical energy generated by the generator by keeping the air pressure delivered to the internal combustion engine at the desired level.
Another object of the invention is to enable the compressor and turbine to be used as controllable brake by creating separately controllable resistors at both the exhaust outlet and the air inlet by controlling of the speeds of the compressor and the turbine separately.
Another aim of the invention is to reduce the extra cost, maintenance and repair workload of the lubrication system and the risk of the occurrence of the technical problems by eliminating the bearing and lubrication need of the turbo system thanks to the operation of the compressor and the turbine on the separate shafts.
Another aim of the invention is to increase the response rate and efficiency of the system by using separate motor and generator instead of a two-way electric machine operating both generator and electric motor on the same shaft.
Another aim of the invention is to allow the compressor to operate at the lower temperatures compared to the conventional systems by allowing the compressor side to be less impacted from the high temperatures on the turbine side and so, to allow to be enable to operate with low-cost materials (e.g. plastic) by allowing greater freedom in the material selection for compressor, thanks to the separation of the compressor and turbine from the same shaft onto the different shafts.
Another aim of the invention is to eliminate the necessity of the system to be in block from (for making the system more flexible) by facilitating the placement of the system by separating the compressor, electric machine and turbine from each other and consequently, to minimize the losses in the gas flow system by reducing the number of twisted connections and sharp turns in this twists which increase losses in the gas flow system, thanks to the elimination of the close positioning. Another aim of the invention is to allow the size of the two components to be independently selected (flexibility in the system design) from each other thanks to the separation of the compressor and turbine from each other.
Another aim of the invention to ensure the response rate of compressor and consequently the response rate of the system to be greater than the response rate of the compressor driven by the turbine thanks to the operation of the compressor driven by bidirectional electric machine instead of the turbine and the system therefore.
Description of the Figures
In Figure 1 , the basic components of the internal combustion engine comprising the present electric turbo system is seen.
In Figure 2, the basic components and operation diagram of an internal combustion engine comprising conventional turbo are given.
In Figure 3, the basic components and operation diagram of an internal combustion engine comprising conventional electric turbo are shown.
Reference Numbers
1. Electric turbo
2. Controller
3. Compressor motor
4. Compressor
5. Intercooler
6. Suction manifold
7. Internal combustion engine
8. Exhaust manifold
9. Turbine
10. Turbine generator
11. Battery
12. Vehicle electronic control unit
13. Power converter
14. Seconder power converter
H. Air
YG. Combustion gas E. Electricity
KB. Control connection
Detailed Description of the Invention
The present invention presents an electric turbo (1) system in which compressor (4) and turbine (9) are located on separate shafts and, compressor (4) is driven (operated) by a compressor motor (3) that is a separate electric motor used instead of turbine (9) in order to eliminate all the disadvantages and limitations caused by the presence of the compressor and the turbine on the same shaft in the conventional electric turbo systems and so, in which system is made more efficient, optimal, scalable and flexible by using a separate motor and generator instead of a single machine operating as a motor-generator and, the working principle therefore.
Turbo system which allows more fuel to burn in the engine by sending (compressed) air above atmospheric pressure to the internal combustion engine and thus enables more power to be generated from the engine, is a kind of turbomachine that takes its motion energy from exhaust gas (combustion gas). A conventional turbo is basically composed of a compressor operating on the suction side and a turbine operating on the exhaust side. The compressor and turbine are connected to each other by means of a shaft and are bedded in a bearing body. The exhaust gases hit the turbine propeller and then, rotates the rotor consisting of the turbine propeller, shaft and compressor propeller. With this rotational movement, the compressor propeller increases the pressure and density of the air by sucking and compressing it. The compressed and dense air which passes to the intercooler after the compressor, cools here and becomes more intense. The condensing air is transmitted to the cylinders via the suction manifold. Since the condensing air contains more oxygen per unit volume, more fuel can be burned during the combustion process occurred in the cylinders. Burning more fuel allows the engine to generates more power by releasing more energy. Thus, it is provided that an internal combustion engine with turbo produces more power than an internal combustion engine without turbo with the same amount of fuel. The basic components and working scheme of an internal combustion engine with turbo are shown in Figure 2.
However, due to the increase in the tendency towards hybrid vehicles and in the constraints in the emission criteria in the recent years, the electric turbo concept has been introduced by changing the turbo systems. Unlike the conventional turbo system, the electric turbo system comprises an external battery and an electric machine operating with the compressor and turbine. The electric machine which operates bidirectionally both as a motor and generator, is located on the same shaft in connection with compressor and turbine. Thus, when the vehicle engine runs at low load, excess turbine energy is converted into electricity by operation of the electric machine in the turbo as a generator. The generated electricity is stored in the external battery located in the turbo system. When the engine runs at high load (when the driver loads on the vehicle pedal), the electric machine in the turbo system starts to operate as a motor and increases the rotation speed of the compressor with the power it takes (draws) from the battery. With the increase of the rotation speed of the compressor, sufficient air pressure is provided by absorbing and compressing air more quickly, thus the reaction time of the system against to the torque requirement shortens. When the turbo starts to provide sufficient air pressure alone, the electric machine stops working as a motor and then, starts to operate as a generator or becomes passive depending on the situation. Thus, as well as shortening the system reaction time, better fuel economy is provided and emissions are reduced thanks to the electric turbo system. Basic components and working scheme of an internal combustion engine with conventional electric turbo are given in Figure 3.
In the conventional electric turbo system, the compressor and the turbine are located on the same shaft and the compressor is driven by the turbine. Since the compressor and the turbine are located on the same shaft, problems occur such as; that the selection of the compressor and turbine cannot be made independently to each other, that the compressor runs at the same cycle with the turbine instead of the desired cycle, therefore the combustion process in the internal combustion engine cannot occur in maximum efficiency and the energy produced by the generator cannot be in the maximum amount, the increasement of maintenance and cost due to the requirement of the bearing and lubrication, the failure of being free for material selection in the compressor side by influencing the compressor side from the high temperature on the turbine side, that the size of the compressor cannot be selected independent from the turbine size, the increasement in the losses in gas flow system with increased number of twists and sharp turns as well as the inability to be flexible in the system design as a result of necessity in the positioning of the turbine, electric machine and compressor in the block form, that the response rate of the compressor driven by the turbine via shaft and consequently the response rate of the system are slow, and as a result it is not possible to use the system in the most efficient way.
In the present electric turbo (1) system, all the above-mentioned problems are turned into advantages thanks to the configuration of the compressor (4) and the turbine (9) on the separate shafts, the driving of the compressor (4) by means of the compressor motor (3) which is an electric motor used instead of the turbine (9) and the using a separate motor and generator instead of a single machine operating as a motor-generator.
The system components of the present invention and the interaction between them are given in Figure 1. As seen from the figure, the present electric turbo (1) system comprises a controller (2) that decides whether the electric turbo (1) system is operated,
a compressor motor (3) that is driven by being controlled by means of mentioned controller (2),
a compressor (4) which is operated with the initial energy taken from the turbine generator (10) and/or from battery (11 ) by mentioned compressor motor (3) and so, provides the suction and the pressurization of the air (H) that will be sent to the internal combustion engine (7) cylinders,
a turbine (9) in which the combustion gases (YG) formed as a result of combustion in the internal combustion engine (7) cylinders are delivered through exhaust manifold (8), a turbine generator (10) which is located on the same shaft with the turbine rotating with the energy of the combustion gases (YG) and thus, generates electricity (E) by starting to operate with the rotation of the turbine (9),
an external battery (11) in which the remaining portion of the electricity (E) (after using for operating of the compressor motor (3)) generated by mentioned turbine generator (10) is stored,
a power converter (13) which, locating between turbine generator (10) outlet and mentioned battery (11) inlet, converts the remaining portion of the electrical (E) energy (after using for operating of the compressor motor (3)) generated by the turbine generator (10) to make it suitable for storage in the battery (11),
a seconder power converter (14) which, locating between the battery (11) and compressor motor (3), coverts the energy received from the battery (11) to the suitable form for usage of the compressor motor (3).
In the present electric turbo (1) system, the compressor (4) and turbine (9) operates on the separate shafts. The energy of the exhaust gases (YG) coming from the internal combustion engine is converted to the electrical energy by the turbine generator (10) connected to the turbine (9). The compressed air (H) required in the cylinders is provided by the compressor (4) driven by a separate compressor motor (3). The electrical (E) energy required to drive the compressor motor (3) is provided by the turbine generator (10). In the case the turbine generator (10) alone cannot drive the compressor motor (3), the energy required for driving the compressor motor (3) is provided by the support of the battery (11) as well as the turbine generator (10). When the turbine generator (10) alone drives the compressor motor (3), the battery (11) is charged with the remaining energy after driving of the compressor motor (3).
In the alternative embodiments of the present invention, the number of the turbines (9) can be increased to increase the amount of the electricity (E) and consequently the charge level of the battery (11). Here, it is possible that the plurality of turbines can be used in different order for different purposes by being connected in parallel to each other while turbines may operate in series (the output of one is connected to the input of the other).
Besides, in the alternative embodiments, the plurality of compressor (4) can be used in series or parallel way for increasing the flow rate and pressure of the air (H) delivered to the cylinders.
The operating principle of the present electric turbo (1) is as follows;
Compressor motor (3) driven by being controlled by the controller (2) operates the compressor (4) with the initial drive energy received from just battery (1 1) or just turbine generator (10) or both of them depending on the situation. The compressor (4) that starts to operate, absorbs the air (H) from the external environment and increases the pressure of the air (H) that will be delivered to the cylinders. In the alternative embodiments of the invention, in which the plurality of compressor (4) can be used in series or parallel way for increasing the flow rate and pressure of the air (H) delivered to the cylinders, the controller (2) provides separate controls of all the compressors (4).
Although not mandatory, the pressurized air (H) at the compressor (4) outlet is made more intense by cooling it by passing it through the intercooler (5), if the vehicle has an intercooler (5) component. Since the condensing air (H) contains more oxygen per unit volume, the combustion process occurred in the cylinder of the internal combustion engine (7) becomes more efficient.
More dense air (H) exiting from the intercooler (5) is sent to the internal combustion engine (7) through the suction manifold (6) and is ensured to be burned in cylinders. After combustion process occurred in the cylinders, the high energy combustion gases (YG) coming to the turbine (9) through the exhaust manifold (8) rotate the turbine (9).
The rotating turbine (9) enables the turbine generator (10) connected to the same shaft with it to operate and generate electricity (E). In the alternative embodiments of the present invention with multiple series or parallel connected turbines (9) to each other in series or in parallel way in the system, the high energy combustion gas (YG) passing through the exhaust manifold (8) can be delivered to a single turbine (9) or to the plurality of turbines (9) that can be operated in different order.
The compressor motor (3) is operated by the electricity (E) generated by the turbine generator (10). After the compressor motor (3) is operated, the remaining electric (E) energy is converted by making it suitable for the battery (1 1) by means of the power converter (13) and is stored in the battery (11). Thus, after the energy stored in the battery (11) is converted to the suitable form for usage of the compressor motor (3) by means of the second power converter (14), as well as providing initial drive energy to the compressor motor (3), it is used together with the turbine generator (10) to operate the compressor motor (3) when the turbine generator (10) alone is not enough to operate the compressor motor (3).
While all these operations are carried out, the loads and temperatures in the internal combustion engine (7) are tracked by the vehicle electronic control unit (12). For maintaining the charge of the battery (11) at the highest level and adjusting the flow rate and pressure of the air (H) required in the cylinders of the internal combustion engine (7), the controller (2) controls the operation of the compressor motor (3) by tracking both the charge level of the battery (1 1) via the control connection (KB) data received from the battery (1 1) and the temperature value in the internal combustion engine (7) via the control connection (KB) data received from the vehicle electronic control unit (12).
In the conventional electric turbo systems, since the compressor is driven by the turbine, the compressor, electric machine and the turbine must be connected on the same shaft in the system. However, thanks to the present innovative electric turbo (1) system and working method, the compressor (4) is driven by the compressor motor (3) which is a separate electric motor. In the present system, the electric (E) energy required for operating the compressor motor (3) is provided by the turbine generator (10). When the turbine generator (10) alone is not enough to operate the compressor motor (3), the energy required for driving the compressor motor (3) is provided by the support of the battery (11) as well as the turbine generator (10). When the turbine generator (10) alone drives the compressor motor (3), the battery (1 1) is charged with the remaining energy after driving the compressor motor (3). Thus, the followings are becomes possible; the controlling of the compressor (4) and the turbine (9) as independent to each other (operating separately at the desired speeds), the maintaining the air (H) pressure delivered to the cylinders at the desired level, the actualizing the combustion in maximum efficiency, the maximizing the amount of the combustion gases (YG) delivered to the turbine (9) and consequently the amount of the electrical (E) energy generated in the turbine generator (10), the eliminating the bearing and lubrication need that arises due to the location of the turbine, electric machine and compressor on the same shaft, and consequently the eliminating the extra parts and maintenance costs of lubrication system, the increasement of the efficiency by using one-way equipment such as generator and motor instead of electric machine that is two-way equipment, the working with lower cost materials by being free to choose the material of the compressor (4) thanks to that the compressor (4) is prevented from being directly affected by the temperatures coming from the turbine (9), the reduction of the number of twisted connection and sharp turns which increase the losses in the gas flow system by eliminating the necessity of block shaped positioning between the turbine, electric machine and compressor, the increasing in the response rate of the system by driving the compressor (4) with the compressor motor (3) instead of the turbine (9), the independent selection of compressor (4) and turbine dimensions to each other.

Claims

1. An electric turbo (1) system which is used to reduce turbo lag, fuel consumption and emissions in the internal combustion engine (7), and comprising a controller (2) that decides whether the electric turbo (1) system is operated, a compressor (4) which allows the air (H) that will be delivered to the cylinders of the internal combustion engine (7) to be sucked and pressurized,
a turbine (9) in which the combustion gases (YG) formed as a result of combustion in the internal combustion engine (7) cylinders are delivered through exhaust manifold (8), an external battery (11) in which the remaining portion of the generated electricity (E) (after using for operating of the compressor motor (3)) is stored,
a power converter (13) which, locating between turbine generator (10) outlet and mentioned battery (11) inlet, converts the remaining portion of the electrical (E) energy (after using for operating of the compressor motor (3)) generated by the turbine generator (10) to make it suitable for storage in the battery (11),
a seconder power converter (14) which converts the energy received from the battery (11) to the suitable form for usage of the compressor motor (3) and, it is characterized by comprising
a compressor (4) and a turbine (9) which are located on the separate shafts, and, for allowing them to locate on the separate shafts; it also comprises
compressor motor (3) which, driven by being controlled by the controller (2), operates the compressor (4) located on the same shaft with the initial drive energy received from just battery (11) or just turbine generator (10) or both of them depending on the situation,
a turbine generator (10) which, locating on the same shaft with the turbine (9), generates electricity (E) by starting to operate with the rotation of the turbine (9), enables firstly mentioned compressor motor (3) to be operated with the electricity (E) it generates, then delivers the remaining electric (E) energy after the operation of the compressor motor (3) to the power converter (13) for converting it to the suitable form for storage in the battery (11).
2. An electric turbo (1) working method for reducing turbo lag, fuel consumption and emissions in the internal combustion engine (7), which comprising a controller (2) that decides whether the electric turbo (1) system is operated, a compressor motor (3) which is driven by being controlled by mentioned controller (2), a compressor (4) which is operated with the driving of mentioned compressor motor (3) and thus, allows the air (H) that will be delivered to the cylinders of the internal combustion engine (7) to be sucked and pressurized,
a turbine (9) in which the combustion gases (YG) formed as a result of combustion in the internal combustion engine (7) cylinders are delivered through exhaust manifold (8), a turbine generator (10) which, locating on the same shaft with the turbine (9) that rotates with the energy of the combustion gases (YG), generates electricity (E) by starting to operate with the rotation of the turbine (9),
an external battery (11) in which the remaining portion of the electricity (E) generated by mentioned turbine generator (10) (after using for operating of the compressor motor (3)) is stored,
a power converter (13) which, locating between turbine generator (10) outlet and mentioned battery (11) inlet, converts the remaining portion of the electrical (E) energy (after using for operating of the compressor motor (3)) generated by the turbine generator (10) to make it suitable for storage in the battery (11),
a seconder power converter (14) which converts the energy received from the battery (11) to the suitable form for usage of the compressor motor (3), and, it is characterized by comprising the following steps driving the compressor (4) with the initial drive energy received from just battery (11) or just turbine generator (10) or both of them depending on the situation by the compressor motor (3) driven by being controlled by the controller (2),
increasing the pressure of the air (H) that will be delivered to the cylinders by sucking of the air (H) from external environment by the compressor (3) starting to operate, providing individual control of all compressors (4) by the controller (2), in the alternative configurations with more than one compressor (4),
although not compulsory, making the pressurized air (H) at the compressor (4) outlet denser by cooling by passing it through the intercooler (5) component, if the vehicle has an intercooler (5) component, delivering of the air (H) exiting from the intercooler (5) to the internal combustion engine
(7) through the suction manifold (6) and burning of the delivered air (H) in the cylinders, rotating the turbine (9) by means of the high energized combustion gases (YG) coming through the exhaust manifold (8) tor he turbine (9) after the combustion occurred in the cylinders,
providing the turbine generator (10) that is located on the same shaft with the rotating turbine (9), to operate and to generates electricity (E),
delivering the high energy combustion gas (YG) passing through the exhaust manifold
(8) to a single turbine (9) or to more than one turbine (9) which can be operated in different order for different purposes, in the alternative configurations with more than one turbine (9),
operating the compressor motor (3) with the electricity (E) generated by the turbine generator (10),
storing the remaining energy after the compressor motor (3) is operated, in the battery (11) by converting it to the suitable form for the battery (11) via power converter (13), using the energy stored within the battery (11) with the turbine generator (10) to operate compressor motor (3) when the turbine generator (10) is not enough alone as well as using it by delivering initial energy to the compressor motor (3) via seconder power converter (14).
3. An electric turbo (1) system according to Claim 1 , wherein one-way operating compressor motor (3) and turbine generator (10) with higher efficiency are used instead of a two-way electric machine operating both as generator and as electric motor on the same shaft.
4. An electric turbo (1) working method according to Claim 2, wherein the controller (2) checks the operation of compressor motor (3) by tracking the charge level of the vehicle battery (12) via the control connection (KB) data received from the battery (11), the temperature value in the internal combustion engine (7) via the control connection (KB) data received from the vehicle electronic control unit (12) in order for maintaining the charge of the battery (11) at highest level and adjusting the flow rate and pressure of the air (H) required in the cylinders of the internal combustion engine (7).
5. An electric turbo (1) system according to Claim 1 or 3 wherein it comprising more than one turbine (9) in alternative embodiments.
6. An electric turbo (1) system according one of the preceding claims, wherein the plurality of turbines (9) can be used in different order for different purposes by being connected in parallel to each other while turbines (9) may operate in series by connecting the output of turbine (9) to the input of the other.
7. An electric turbo (1) system according to Claim 1 wherein it comprises more than one compressor (4) in alternative embodiments.
8. An electric turbo (1) system according to one of the preceding claims, wherein the plurality of compressor (4) can be used in the different order for different purposes by being connected in parallel to each other while compressors (4) may operate in series by connecting the output of compressor (4) to the input of the other.
EP19901019.0A 2018-12-19 2019-12-19 An electric turbo system in which efficiency is increased by having compressor and turbine on the separate shafts, and working principle thereof Pending EP3902988A4 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
TR2018/19790A TR201819790A2 (en) 2018-12-19 2018-12-19 AN ELECTRIC TURBO SYSTEM AND RELATED WORKING METHOD WITH THE COMPRESSOR AND THE TURBINE ON SEPARATE SHAFTS, INCREASING EFFICIENCY
PCT/TR2019/051115 WO2020130991A2 (en) 2018-12-19 2019-12-19 An electric turbo system in which efficiency is increased by having compressor and turbine on the separate shafts, and working principle thereof

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EP3902988A4 EP3902988A4 (en) 2022-11-09

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US7958727B2 (en) * 2005-12-29 2011-06-14 Honeywell International Inc. Electric boost compressor and turbine generator system
GB0624599D0 (en) * 2006-12-09 2007-01-17 Aeristech Ltd Engine induction system
JP5177401B2 (en) * 2008-05-30 2013-04-03 株式会社Ihi Method and system for warming up exhaust gas purification catalyst
JP2010190145A (en) * 2009-02-19 2010-09-02 Ihi Corp Supercharging and exhaust emission control system of internal combustion engine
GB201010443D0 (en) * 2010-06-22 2010-08-04 Aeristech Ltd Controller
JP6621043B2 (en) * 2016-03-09 2019-12-18 三菱重工エンジン&ターボチャージャ株式会社 SUPERCHARGE SYSTEM, SUPERCHARGE SYSTEM POWER SUPPLY DEVICE, SUPERCHARGE SYSTEM POWER SUPPLY CONTROL METHOD, AND ENGINE SYSTEM

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