WO2016171955A1

WO2016171955A1 - Turbo configuration

Info

Publication number: WO2016171955A1
Application number: PCT/US2016/027104
Authority: WO
Inventors: John Shutty
Original assignee: Borgwarner Inc.
Priority date: 2015-04-20
Filing date: 2016-04-12
Publication date: 2016-10-27

Abstract

A number of variations may include a product which may include a vehicle exhaust turbine, an electric generator operatively connected to the vehicle exhaust turbine, an electric motor constructed and arranged to operate at a first voltage, the electric motor connected to a vehicle intake gas compressor, the electric generator electrically connected to the electric motor through an interface, and at least one other vehicle component connected to the interface, and wherein the at least one other vehicle component is constructed and arranged to operate at a second voltage, which is less than the first voltage.

Description

TURBO CONFIGURATION

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of the United States Provisional

Application No. 62/149,794 filed April 20, 2015.

Select examples of variations within the scope of protection sought will become more fully understood from the detailed description and the accompanying drawings, wherein:

The Figure shows a schematic illustration of a vehicle system according to a number of variations.

The following description of the variations is merely illustrative in nature and is in no way intended to limit the scope of protection sought, its application, or uses.

FIG. 1 illustrates a number of variations that may include a vehicle having a first electrical architecture that operates at a relatively low voltage, for example, but not limited to, equal to or less than 50 volts. In a number of variations the vehicle may also include one or more components that operate at a relative high voltage for example, but not limited to, 100-650 volts. In a number of variations an interface 30 may be provided that may be a single module with a variety of components therein or may be a collection of components operating together. In a number of variations, the interface 30 may include a switch 32 for controlling the flow of electricity therethrough. The interface 30 may also include a converter 34 for converting electricity from a first voltage to a second voltage, or for converting alternating current to direct current, or vice versa. The interface 30 may be operated to deliver electricity to the one or more components that operate at the relative high voltage, and may control the use electricity delivered to and from an number of components and may control the storage of electrical power.

Referring in greater detail to FIG. 1 , in a number of variations a vehicle may include a product 10 which may include a combination of any one or more of the following components. In a number of variations, the vehicle may include an engine 12 which may be operatively connected to a radiator 14 having coolant lines 16 plumbed between the radiator 14 and the engine 12 to cool the same. An intake conduit (line) 18 may be operatively connected to the engine 12 to allow air and/or recirculated exhaust gas or other gases to enter combustion chambers of the engine 12. Fuel combusted in the engine 12 produces exhaust gas which may exit the engine 12 through the exhaust conduit (line) 19. The exhaust conduit 19 may be operatively connected to a turbine 20 to drive the same. In a number of variations, a generator 22 may be connected to the turbine 20 to produce electricity as a turbine is rotated by exhaust gas flowing therethrough. The electric generator 22 may be operatively connected to an electric motor 24. The electric motor 24 may be constructed and arranged to operate at a first voltage and to drive a compressor 26. The compressor 26 may be operatively connected to the intake conduit 18 to compress air or other gases flowing through the intake conduit 18. The electric generator 22 may deliver electricity through an electrical connection 28 to an interface 30. Again the interface 30 may be a single module with a variety of components therein or may be a collection of components operating together. In a number of variations, the interface 30 may include a switch 32 for controlling the flow of electricity therethrough. The interface 30 may also include a converter 34 for converting electricity from a first voltage to a second voltage, or for converting alternating current to direct current, or vice versa. In a number of variations, the interface 30 may also include a controller 36 for controlling the switch 32 and/or the converter 34, or for controlling other components. In a number of variations, the interface 30 may include one or more supplemental devices 38 to carry out operations as desired with respect to the generator 22, electric motor 24, or other components in the vehicle. The interface 30 may be connected to the electric motor 24, for example, by a second electrical connection 40. The product 10 may also include at least one other vehicle component 42 such as, but not limited to, an energy storage device constructed and arranged to operate at a second voltage, which is less than the first voltage. For example, the electric motor 24 may be constructed and arranged to operate at more than 48 volts, for example but not limited to, 100-650 volts or any range therebetween including 300-600 volts. At least one other vehicle component 42 may be a storage battery constructed and arranged to store energy at less than 300 volts, for example but not limited to, 48-12 volts. The electric generator 22 also may be constructed and arranged to operate at third voltage which may be the same or different than the first voltage. For example the generator 22 may operate at more than 48 volts, for example but not limited to, 100-650 volts or any range therebetween including 300-600 volts. Another vehicle component 44 such as, but not limited to, a boardnet may be constructed and arranged and operatively connected to the interface 30 to communicate therewith, including sending signals and/or power thereto. In a number of variations, the radiator 14 may be plumbed to provide cooling to at least one of the turbine 20, generator 22, interface 30, electric motor 24, compressor 26, interface 30, switch or converter 34.

The inclusion of the interface 30 may allow for the use of components that operate at a higher voltage than the standard first electrical architecture for the vehicle. For example, a high voltage motor 24 may be used for rapid compression of air and delivery to the engine 12 in response to an increase the load demand on the engine 12. In another variation the generator 22 may be operated at a high voltage motor to rapidly spin up the turbine 20 in response to increases in the load demand on the engine 12.

In a number of variations an alternator 50 may be operatively connected to the engine 12 to generate electricity and may deliver the electricity to the interface 30 through electrical line 52. Electricity generated from the alternator 50 may be converted for use in one or more high voltage components such as, but not limited to, the electric motor 24 or the generator 24 operated as a motor. Energy may be supplied form a variety of sources including at least one of the alternator 50 or the storage device 42 to the one or more high voltage components when required by the same.

As mentioned, electrical power may be used to drive the turbine generator (motor) 22 to get the turbine 20 spinning during an acceleration to quicken the acceleration. In a number of variations, under steady state conditions wherein there may be very high low end torque, additional power from the alternator 50 or storage device 42 may be provide to supplement the compressor motor 24 so that the engine 12 can produce more output.

In a number of variations a ripple load/drive may be provided on the turbine generator 22 to control the speed of the turbine 20 throughout the combustion cycle to try to keep the speed of the turbine 20 at the predetermined speed relative to the speed of the exhaust gas. A number of variations may include a method of controlling the turbine 20 speed by adjusting the load on the generator 22. In a number of variations the delivery of power may be increased or decreased to the compressor motor 24 and/or turbine generator/motor 22 to keep the speed of the turbine 20 at the predetermined speed relative to the speed of the exhaust gas. In a number of variations, the system 10 may be operated using a method which may include delivering stored energy from, for example, the first vehicle component 42 such as an energy storage device at the second voltage through the interface 30. The second voltage may be converted by the converter 34 to the first voltage and electricity at the first voltage may be delivered to the electric motor 24 during transient conditions wherein the operator is requesting more power from the engine 12 by, for example, depressing a vehicle accelerator. Such a method reduces or eliminates turbo lag and causes the compressor 26 to spin at a rate faster than it would using only electricity from the generator 22 produced by a relatively low spinning turbine 20. During rapid increasing load demand situations compressed air/gases may be delivered to the engine by the compressor 26 operated by the electric motor 24 using energy from the storage device 42, and optionally with electricity from the generator 22. Thereafter, the interface 30 and/or the boardnet 44 may send control signals to stop delivery of power from the storage device 42 when the exhaust flowing through the turbine 20 is sufficient to generate electricity by the generator 22 to meet the load demand of the electric motor 24..

In a transient situations wherein the vehicle is decelerating, coasting or idling, electricity produced by the generator 22 may be converted by the converter 34 to a second voltage and energy stored at the second voltage in the storage device 42 if the electricity being produced by the generator 22 is in excess of that needed to drive the electric motor 24 based upon operator power commands. There may be a number of other situations in which the generator 22 is producing more power/electricity than is needed by the electric motor 24 and such power/electricity can be converted, for example, to 48 volts and stored as energy in the storage device 42. In a number of variations, the second vehicle component 44 such as the boardnet may operate a fourth voltage such as 12 volts.

The following description of variants is only illustrative of components, elements, acts, product and methods considered to be within the scope of the invention and are not in any way intended to limit such scope by what is specifically disclosed or not expressly set forth. The components, elements, acts, product and methods as described herein may be combined and rearranged other than as expressly described herein and still are considered to be within the scope of the invention.

Variation 1 may include a product comprising: a vehicle exhaust turbine; an electric generator operatively connected to the vehicle exhaust turbine; an electric motor constructed and arranged to operate at a first voltage, the electric motor connected to a vehicle intake gas compressor; the electric generator electrically connected to the electric motor through an interface; at least one other vehicle component connected to the interface; and wherein the at least one other vehicle component is constructed and arranged to operate at a second voltage, which is less than the first voltage.

Variation 2 may include a product as set forth in Variation 1 wherein the interface includes a switch to control the flow of electricity from the generator through the interface.

Variation 3 may include a product as set forth in any of Variations 1 -2 wherein the generator produces electricity at a third voltage, and wherein the interface includes a converter to convert electricity from the generator from the third voltage to a second voltage or first voltage, or from the second voltage to the first voltage.

Variation 4 may include a product as set forth in any of Variations 1 -2 wherein the interface includes a switch to control the flow of electricity from the generator through the interface, and includes a converter to convert electricity from the generator to a second voltage or from the second voltage to the first voltage, and a controller to control at least one of the switch or converter.

Variation 5 may include a product as set forth in any of Variations 1 -4 wherein the interface includes a converter to convert electricity from the generator from a third voltage to a second voltage or from the second voltage to the first voltage, and wherein the at least one other vehicle component connected to the interface comprises an energy storage device construct and arranged to operate at the second voltage.

Variation 6 may include a product as set forth in any of Variations 1 -5 wherein the second voltage is less than 300 volts.

Variation 7 may include a product as set forth in any of Variations 1 -5 wherein the second voltage is equal to or less than 50 volts.

Variation 8 may include a product as set forth in any of Variations 1 -7 wherein the first voltage ranges from 300-600 volts.

Variation 9 may include a product as set forth in any of Variations 1 -8 wherein the generator is constructed and arranged to operate at a third volt which is greater than 48 volts.

Variation 10 may include a product as set forth in any of Variations 1 -9 wherein the generator is constructed and arranged to operate at a third volt ranging from 100-650 volts.

Variation 1 1 may include a product as set forth in any of Variations 1 - 10 further comprising a vehicle boardnet constructed and arranged to operate at a fourth voltage.

Variation 12 may include a product as set forth in any of Variations 1 - 10 further comprising a vehicle boardnet constructed and arranged to operate at a 12 volts.

Variation 13 may include a method comprising: providing a product comprising a vehicle exhaust turbine; an electric generator operatively connected to the vehicle exhaust turbine; an electric motor constructed and arranged to operate at a first voltage, the electric motor connected to a vehicle intake gas compressor; the electric generator electrically connected to the electric motor through an interface; at least one energy source connected to the interface; and wherein the at least one energy source is constructed and arranged to operate at a second voltage, which is less than the first voltage; converting energy from the at least one energy source from the second voltage to electricity at the first voltage and delivering the converted electricity at the first voltage to the electric motor to drive the compressor or delivering the converted electricity at the first voltage to the electric generator to spin the turbine. Variation 14 may include a method as set forth in Variation 13 wherein the at least one energy source is at least one of a storage battery, an alternator connected to an engine, or the electric generator operatively connected to the vehicle exhaust turbine.

Variation 15 may include a method as set forth in any of Variations 13-

14 and further comprising stopping converting energy from the at least one energy source from the second voltage to electricity at the first voltage and delivering the converted electricity at the first voltage to the electric motor when the generator generates sufficient electricity from exhaust gas flowing through the turbine to at least meet the load demand of an engine connected to the intake gas compressor.

Variation 16 may include a method as set forth in any of Variations 13-

15 wherein the further comprising providing supplemental energy to the electric motor or to the electric generator from at least one of a storage battery or an alternator connected to an engine.

Variation 17 may include a method as set forth in any of Variations 14-

16 further comprising converting electricity generated by a generator at a third voltage to electricity at the second voltage and storing the electricity at the second voltage in the at least one energy storage device when the load demand on the electric motor is decreased and the electricity generated by the generator is in excess of the decreased load demand of the electric motor.

Variation 18 may include a method as set forth in any of Variations 13-

17 and further comprising increasing or decreasing electrical power delivered to at least one of the compressor motor or electrical generator to keep the speed of the turbine at the predetermined speed relative to the speed of the exhaust gas.

The above description of select variations within the scope of the invention is merely illustrative in nature and, thus, variations or variants thereof are not to be regarded as a departure from the spirit and scope of the invention.

Claims

CLAIMS What is claimed is:

1 . A product comprising:

a vehicle exhaust turbine;

an electric generator operatively connected to the vehicle exhaust turbine;

an electric motor constructed and arranged to operate at a first voltage, the electric motor connected to a vehicle intake gas compressor; the electric generator electrically connected to the electric motor through an interface;

at least one other vehicle component connected to the interface;

and wherein the at least one other vehicle component is constructed and arranged to operate at a second voltage, which is less than the first voltage.

2. A product as set forth in claim 1 wherein the interface includes a switch to control the flow of electricity from the generator through the interface.

3. A product as set forth in claim 1 wherein the generator produces electricity at a third voltage, and wherein the interface includes a converter to convert electricity from the generator from the third voltage to a second voltage or first voltage, or from the second voltage to the first voltage.

4. A product as set forth in claim 1 wherein the interface includes a switch to control the flow of electricity from the generator through the interface, and includes a converter to convert electricity from the generator from the first voltage to a second voltage or from the second voltage to the first voltage, and a controller to control at least one of the switch or converter.

5. A product as set forth in claim 1 wherein the interface includes a converter to convert electricity from the generator from a third voltage to a second voltage or from the second voltage to the first voltage, and wherein the at least one other vehicle component connected to the interface comprises an energy storage device construct and arranged to operate at the second voltage.

6. A product as set forth in claim 5 wherein the second voltage is less than 300 volts.

7. A product as set forth in claim 1 wherein the first voltage equal to or less than 50 volts.

8. A product as set forth in claim 1 wherein the first voltage ranges from 100-650 volts.

9. A product as set forth in claim 1 wherein the generator is constructed and arranged to operate at a third volt which is greater than 48 volts.

10. A product as set forth in claim 1 wherein the generator is constructed and arranged to operate at a third volt ranging from 100-650 volts.

1 1 . A product as set forth in claim 1 further comprising a vehicle boardnet constructed and arranged to operate at a fourth voltage.

12. A product as set forth in claim 1 further comprising a vehicle boardnet constructed and arranged to operate at a 12 volts.

13. A method comprising:

providing a product comprising a vehicle exhaust turbine;

an electric generator operatively connected to the vehicle exhaust turbine;

an electric motor constructed and arranged to operate at a first voltage, the electric motor connected to a vehicle intake gas compressor; the electric generator electrically connected to the electric motor through an interface; at least one energy source connected to the interface;

and wherein the at least one energy source is constructed and arranged to operate at a second voltage, which is less than the first voltage; converting energy from the at least one energy source from the second voltage to electricity at the first voltage and delivering the converted electricity at the first voltage to the electric motor to drive the compressor or delivering the converted electricity at the first voltage to the electric generator to spin the turbine.

14. A method as set forth in claim 13 wherein the at least one energy source is at least one of a storage battery, an alternator connected to an engine, or the electric generator operatively connected to the vehicle exhaust turbine.

15. A method as set forth in claim 13 further comprising stopping converting energy from the at least one energy source from the second voltage to electricity at the first voltage and delivering the converted electricity at the first voltage to the electric motor when the generator generates sufficient electricity from exhaust gas flowing through the turbine to at least meet the load demand of an engine connected to the intake gas compressor.

16. A method as set forth in claim 13 wherein the further comprising providing supplemental energy to the electric motor or to the electric generator from at least one of a storage battery or an alternator connected to an engine.

17. A method as set forth in claim 13 further comprising converting electricity generated by a generator at a third voltage to electricity at the second voltage and storing the electricity at the second voltage in the at least one energy storage device when the load demand on the electric motor is decreased and the electricity generated by the generator is in excess of the decreased load demand of the electric motor.

18. A method as set forth in claim 13 further comprising increasing or decreasing electrical power delivered to at least one of the compressor motor or electrical generator to keep the speed of the turbine at the predetermined speed relative to the speed of the exhaust gas.