WO2017023686A1

WO2017023686A1 - Turbocharger assist system using organic rankine cycle fluid energy

Info

Publication number: WO2017023686A1
Application number: PCT/US2016/044438
Authority: WO
Inventors: Brock Fraser
Original assignee: Borgwarner Inc.
Priority date: 2015-08-05
Filing date: 2016-07-28
Publication date: 2017-02-09

Abstract

A number of variations may include a system which may include an Organic Rankine Cycle that may include at least a first boiler operatively connected to a vehicle engine system to recover waste heat therefrom. The Organic Rankine Cycle may include an organic working fluid. The Organic Rankine Cycle may be operatively connected to a turbocharger system to provide turbocharger assist using energy from the working fluid.

Description

TURBOCHARGER ASSIST SYSTEM USING ORGANIC RANKINE

CYCLE FLUID ENERGY

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of United States Provisional Application No. 62/201 ,229 filed August 5, 2015.

TECHNICAL FIELD

The field to which the disclosure generally relates to include turbocharger assist systems using Organic Rankine Cycle fluid energy and methods of making and using the same.

BACKGROUND

Vehicles may be operated in a way which produces engine waste heat.

SUMMARY OF ILLUSTRATIVE VARIATIONS

Other illustrative variations within the scope of the invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while disclosing variations within the scope of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Select examples of variations within the scope of the invention will become more fully understood from the detailed description and the accompanying drawings, wherein: Figure 1 is a schematic illustration of a system including an Organic Rankine Cycle operatively connected to an engine system according to a number of variations.

Figure 2 is a schematic illustration of a turbocharger and a turbocharger assist turbine operatively connected to the turbocharger according to a number of variations.

DETAILED DESCRIPTION OF ILLUSTRATIVE VARIATIONS

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

A number of variations may include a system which may include an Organic Rankine Cycle that may include at least a first boiler operatively connected to a vehicle engine system to recover waste heat therefrom. The Organic Rankine Cycle may include an organic working fluid. The Organic Rankine Cycle may be operatively connected to a turbocharger system to provide turbocharger assist using energy from the working fluid. In operation, vehicles may be operated in a way that produces engine waste heat. This may create an opportunity to harvest some of this engine waste heat using an Organic Rankine Cycle system. In the presences of an Organic Rankine Cycle system, the working fluid may be intermittently used to assist in overcoming "turbo lag".

A number of variations are illustrated in Figs. 1 -2, and may include a system 10 that may include an Organic Rankine Cycle 14 and a turbocharger assist turbine 26 operatively connected together to use energy from a working fluid of the Organic Rankine Cycle 14 to rotate a turbocharger assist turbine 26. The turbocharger assist turbine 26 may include a

turbocharger assist turbine shaft 28 which may be connected to a turbine 22 or a turbine shaft 24 which may be operatively connected to a compressor 20 of the turbocharger 18. An engine system 1 1 may include an air intake line 30 operatively connected to the compressor 20 of the turbocharger 18. An air charge cooler 32 may be provided in the air intake line 30 and an air charge cooler bypass line 34 which may have a valve 36 therein, may be provided and constructed and arranged so that at least a portion of the air flowing through the air charge line 30 may bypass the air charge cooler 32 when desired. An air intake manifold 38 may be operatively connected to the air charge line 30 and may be constructed and arranged to provide air flow into a plurality of combustion chambers 42 of an engine 40. An exhaust manifold 44 may be operatively connected to the engine 40 to receive exhaust expelled from the plurality of combustion chambers 42. An exhaust conduit 45 may be provided between the exhaust manifold 44 and an exhaust gas recirculation valve (EGR) 46. A high pressure EGR loop line 48 may be connected to the EGR valve 46. A first boiler 50 of the Organic Rankine Cycle may be provided in the high pressure EGR loop line 48. The first boiler 50 may have an inlet 56 for working fluid of the Organic Rankine Cycle to enter the first boiler 50 and an outlet 58 for the working fluid to exit the first boiler 50. An Organic Rankine Cycle first boiler bypass line 52 may be provided and may include a valve 54 therein constructed and arranged to allow at least a portion of the exhaust flowing through the high pressure EGR loop line 48 to bypass the first boiler 50 when desired. The high pressure EGR loop line 48 may be connected from the first boiler 50 and bypass line 52 to the air intake manifold 38 directly or indirectly.

An exhaust conduit 47 may extend from the EGR valve 46 to the turbine 22 of the turbocharger 18. Exhaust from the turbine 22 may exit through exhaust line 49 and a second boiler 62 operatively connected to the exhaust line 49. The second boiler 62 may include an inlet 64 for allowing the working fluid from Organic Rankine Cycle to enter the second boiler 62 through conduit 71 from the three way valve 68 and an outlet 66 for allowing the working fluid to exit the second boiler 62. Conduit 71 may be connected from the outlet 66 of the second boiler 62 to the first three way valve 78. An exhaust line 51 may be operatively connected to the second boiler 62 to discharge the exhaust to the atmosphere. If desired, a low pressure EGR loop may be connected to exhaust segment 51 and to the air intake line 30.

The Organic Rankine Cycle 14 may include a three-way valve

78 connecting working fluid lines 76 from the second boiler 62 and/or the first boiler 50. Working fluid line 84 may be connected to the three-way valve 78 and to a turbocharger assist turbine 26 which expands the working fluid. Working fluid may exit the turbocharger assist turbine 26 through working fluid line 86 and may be connected to a working fluid line segment 88 exiting an Organic Rankine Cycle expander 82.

A working fluid line 88 may be connected from the three-way valve 78 to the Organic Rankine Cycle expander 82. Working fluid line 88 may be connected to a condenser 90 which may include a cooling fluid inlet line 92 and a cooling fluid outlet line 94. A working fluid line 96 may be connected from the condenser 90 to a pump 98 constructed and arranged to increase the pressure of the working fluid. Working fluid line 100 may be connected to the pump 98 and to a three-way valve 68 which may control the flow of working fluid through working fluid line 70 entering the first boiler 50. Working fluid line 72 may extend from the three-way valve 68 to the inlet 64 of the second boiler 62.

A controller 102 may be provided and constructed and arranged to receive input signals 104 from a plurality of sensors including, but not limited to, a sensor 108 on the engine, a sensor 1 10 on the compressor 20, and/or a sensor 1 12 in one of the working fluid lines, for example 88. The controller 102 may send an output signal 106 to control one or more components of the system 10.

The turbocharger assist turbine 26 may be a sealed system to prevent leakage of the working fluid of the Organic Rankine Cycle. In a number of variations, a turbocharger assist shaft 28 may be provided connecting the turbocharger assist turbine 26 to the compressor 20. In a number of variations the turbocharger assist turbine 26 may be operatively connected through the turbocharger shaft 24 used by the turbine 22 of the turbocharger system 18.

A number of variations are illustrated in Figure 2 which may include a turbocharger assist turbine 26 operatively connected to produce shaft work from the working fluid entering the turbocharger assist turbine 26 through line 84 and exiting through line 86. A turbocharger assist turbine 26 may be connected to a shaft 28 and a clutch mechanism 107 including a plurality of clutch plates 103, 105. One of the clutch plates 105 may be connected to a shaft 23 connected to the turbocharger turbine 22. If desired, the turbocharger 18 may be operated to disconnect the turbocharger assist turbine 26 when working fluid is not flowing therethrough. The ORC expander 82 may be constructed and arranged to produce shaft work and may include an expander fan wheel (not shown) connected to a shaft 1 14 of an electric generator 1 16. Electricity product by the generator 1 16 may be delivered to a converter 1 18, if necessary, and then stored in a battery 122. A battery charge controller 120 may be provided to control the timing, rate and parameters of the battery charging. An electrical outlet line 123 may be connected to the battery 122 and at least one of the ORC pump 98, a condenser coolant pump 124 or another component in the vehicle to selectively supply power thereto.

In a number of variations the controller 102 or other devices may be used to determine a rapid increase in the load demand on the engine, such as in transient conditions which may include but are not limited to when the vehicle operated rapid depresses the accelerator to speed up the vehicle to pass a vehicle, for a rapid lane change or similar situations. To reduce turbocharger lag and/or more rapidly respond to the vehicle operator demand the controller 102 or other device may cause the ORC three way value 78 to move so that at least a portion of the working fluid bypasses the ORC expander 82 and flow to the turbocharger assist turbine 26 to rotate that same. The turbocharger assist turbine 26 assists in the rotation the compressor 20 thereby charging more inlet gas into the engine 40 to produce more power from the engine 40.

At point A (conduit 84) in Figure 1 the pressure of the working fluid may range from about 15 bar to about 30 bar, for example 25 bar, the temperature may range from about 200 degrees C to about 320 degrees C, for example 300 degrees C, and the flow rate may range from about 0.05 kg/sec to about 0.15 keg/sec, for example 0.1 kg/second. The turbocharge assist turbine 26 may be a sealed to prevent leakage of the working fluid.

The working fluid may flow through conduit 85 back to the conduit 88 exiting the expander 82, for example at point B in Figure 1 up stream of the condenser 90. At point B the in Figure 1 the pressure of the working fluid may range from about 1 .5 bar to about 3 bar, for example 2 bar, the temperature may range from about 200 degrees C to about 300 degrees C, for example 280 degrees C, and the flow rate may range from about 0.05 kg/sec to about 0.15 kg/sec, for example 0.1 kg/second. In a number of variations suitable Rankine Cycle fluids may include, but are not limited to, at least one of ethanol, water, toluene, methanol, or refrigerants.

In a number of variations the controller 102 may be an electronic control module which may be connected to a plurality of vehicle components including, but not limited to, the engine 40, the generator 58, mechanical energy recovery component 72, and/or the thermal energy recovery

component 62. The controller 102 may include hardware and software constructed and arranged to control the components including the

components of the Organic Rankine Cycle 14 and the turbocharger assist turbine 26. It is also contemplated that a second electronic control module (SECM) may be provided to control the operation of one or more components in the vehicle. The second electronic control module may include hardware and software constructed and arranged to carry out a variety of operating processes associated with the components.

The ECM and SECM may each receive and process input from the various sensors and transmit output signals to various actuators. The ECM and the SECM may be operated independently of one another or the SECM may be a slave to the ECM in at least some operations and process control situations. The ECM and SECM each may include an electrical circuit, an electronic circuit or chip, and/or computer. In an illustrative computer variation, the ECM and the SECM each generally may include one or more processors, memory devices that may be coupled to the processors, and one or more interfaces coupling the processors to one or more other devices. Although not known, the processors and other powered system devices may be supplied with electricity by a power supply. The power supply may be one or more of batteries, fuel cells, or the like. The processors may execute instructions that provide at least some functionality for the disclosed system and methods.

As used herein, the term instructions may include, but are not limited to, control logic, computer software and/or firmware, programmable instructions, or other suitable instructions. The processor may include, for example, one or more microprocessors, microcontrollers, application specific integrated circuits, programmable logic devices, field programmable gate arrays, and/or any other suitable type of electronic processing devices. The memory device may also be configured to provide storage for data received by or loaded to the engine system, and/or for processor executable

instructions. The data and/or instructions may be stored, for example, as lookup tables, formulas, algorithms, maps, models, and/or any other suitable format.

The memory may include RAM, ROM, EPROM, and/or any other suitable type of storage article and/or device. Additionally, the

interfaces may include analog, digital or digital analog converters, signal conditioners, amplifiers, filters, other electronic devices or software modules, and/or any other suitable interfaces. The interfaces make and form to, for example, RS232, parallel, small computer system interface, universal serial bus, CAN, MOST, LIN, flex ray, and/or any other suitable protocols. Moreover, the interfaces may include circuits, software, firmware, or any other device to assist or enable the ECM and the SECM each in communicating with other devices.

The methods or parts thereof may be implemented in a computer program product including instructions carried out on a computer readable medium for use by one or more processors in order to implement one or more of the method steps. The computer program product may also include one or more software programs comprised of program instructions and source code, object code, executable code, or other formats; one or more firmware programs; or hardware description language files; and any program related data. The data may include data structures, lookup tables, or data in any other suitable format. The program instructions may include program modules, routines, programs, objects, components, etc. The computer program may be executed on processor or in multiple processors in

communication with one another.

The programs can be embodied on a computer readable media, which can include one or more storage devices, articles of manufacturer, etc. Illustrative computer readable media include computer system memory, RAM, ROM, semi-conductor memory, electronically erasable programmable readonly memory, flash memory, magnetic or optical discs or tapes, etc. The computer readable medium may also include computer to computer connections, for examples, when data is transferred or provided over a network or other communications network whether wired, wireless or a combination thereof. Any combination of the above examples is also included within the scope of computer readable media. It is therefore to be understood that the method may be at least partially performed by any electronic articles and/or devices capable of executing instructions corresponding to one or more steps of the disclosed methods.

Empirical models may developed from controlling the operation of one or more of various components including but not limited to the Organic Rankine Cycle 14, turbocharger 18 and turbocharger assist turbine 26 and EGR loops and components thereof and the engines can include lookup tables, maps, and the like that may cross-reference cylinder pressure with oxygen concentration. As used herein, the term model may include any construct that represents something using variables such as a lookup table, map, formula, algorithm, etc. Models may be an application specific in particular to the exact design and performance specifications of any given engine system. In one example, the engine system models in turn may be responsive to engine speed and intake manifold pressure and temperature.

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 system comprising: an Organic

Rankine Cycle having at least a first boiler operatively connected to a vehicle engine system to recover waste heat therefrom, the Organic Rankine Cycle including an organic working fluid, and wherein the Organic Rankine Cycle is operatively connected to a turbocharger system to provide turbocharger assist using energy from the working fluid.

Variation 2 may include a system as set forth in Variation 1 wherein the Organic Rankine Cycle comprise an expander downstream of the first boiler, a condenser downstream of the expander and a pump downstream of the condenser and the first boiler being downstream of the pump.

Variation 3 may include a system as set forth in Variation 2 wherein the first boiler is connected to a high pressure EGR loop connected to an engine of the vehicle engine system.

Variation 4 may include a system as set forth in any of

Variations 1 -3 wherein the Organic Rankine Cycle further comprising a second boiler.

Variation 5 may include a system as set forth in Variation 4 wherein the second boiler is connected to a low pressure EGR loop connected to an engine of the vehicle engine system.

Variation 6 may include a system as set forth in any of

Variations 4-5 wherein the second boiler is down stream of the first boiler.

Variation 7 may include a system as set forth in any of

Variations 2-6 wherein the Organic Rankine Cycle further comprising three way valve constructed and arranged to selectively control of the organic working fluid in a conduit connected at least one of a first boiler or a second boiler to the three way valve and a conduit connected to the three way and a turbocharge assist turbine, and a conduit connected to the three way valve and to a condenser.

Variation 8 may include a system as set forth in Variation 7 further comprising a conduit connected to the turbocharger assist turbine to the conduit connected to the three way valve and to a condenser.

Variation 9 may include a system as set forth in any of

Variations 2-8 wherein the first boiler is connected to a high pressure EGR loop connected to an engine of the vehicle engine system, and the Organic Rankine Cycle further comprising a second boiler connected to a low pressure EGR loop connected to an engine of the vehicle engine system, and a three way valve up stream of the first boiler constructed and arranged to allow flow of the organic working fluid into the first boiler and a conduit connected to the tree way valve and the second boiler so that at least a portion of the organic working fluid can be caused to selective bypass the first boiler.

Variation 10 may include a system as set forth in any of

Variations 1 -9 wherein the working fluid comprises ethanol. Variation 1 1 may include a method comprising: providing an Organic Rankine Cycle having at least a first boiler operatively connected to a vehicle engine system to recover waste heat therefrom, the Organic Rankine Cycle including an organic working fluid, and wherein the Organic Rankine Cycle is operatively connected to a turbocharger system to provide

turbocharger assist using energy from the working fluid, the Organic Rankine Cycle comprise an expander downstream of the first boiler, a condenser downstream of the expander and a pump downstream of the condenser and the first boiler being downstream of the pump, wherein the Organic Rankine Cycle further comprising a first three way valve constructed and arranged to selectively control of the organic working fluid in a conduit connected at least one of a first boiler or a second boiler to the three way valve and a conduit connected to the three way and a turbocharge assist turbine, and a conduit connected to the three way valve and to a condenser, the turbocharge system including a compressor connected to a turbocharger turbine constructed and arranged to turn the compressor; selectively controlling the first three way valve to allow at least a portion of the working fluid to bypass the expander and flow to the turbocharger assist turbine and turn the compressor.

Variation 12 may include a method as set forth in Variation 1 1 wherein the Organic Rankine Cycle further comprising a second boiler connected to a low pressure EGR loop connected to an engine of the vehicle engine system, and a second three way valve up stream of the first boiler constructed and arranged to allow flow of the organic working fluid into the first boiler and a conduit connected to the three way valve and the second boiler so that at least a portion of the organic working fluid can be caused to selective bypass the first boiler; selectively controlling the second three way valve to cause at least a portion of the organic working fluid to bypass the first boiler and flow into the second boiler.

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

Variations 1 1 -12 wherein the first boiler is connected to a high pressure EGR loop connected to an engine of the vehicle engine system.

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

Variations 1 1 -13 further comprising determining if the turbo charge system needs assistance in turning the compressor to respond the load demand on the engine and if so performing the act of selectively controlling the first three way valve to allow at least a portion of the working fluid to bypass the expander and flow to the turbocharger assist turbine and turn the compressor.

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

Variations 1 1 -14 wherein the working fluid comprises ethanol.

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 system comprising:

an Organic Rankine Cycle having at least a first boiler operatively connected to a vehicle engine system to recover waste heat therefrom, the Organic Rankine Cycle including an organic working fluid, and wherein the Organic Rankine Cycle is operatively connected to a turbocharger system to provide turbocharger assist using energy from the working fluid.

2. A system as set forth in claim 1 wherein the Organic Rankine Cycle comprise an expander downstream of the first boiler, a condenser downstream of the expander and a pump downstream of the condenser and the first boiler being downstream of the pump.

3. A system as set forth in claim 2 wherein the first boiler is connected to a high pressure EGR loop connected to an engine of the vehicle engine system.

4. A system as set forth in claim 3 wherein the Organic Rankine Cycle further comprising a second boiler.

5. A system as set forth in claim 4 the second boiler is connected to a low pressure EGR loop connected to an engine of the vehicle engine system.

6. A system as set forth in claim 4 wherein the second boiler is down stream of the first boiler.

7. A system as set forth in claim 2 wherein the Organic Rankine Cycle further comprising three way valve constructed and arranged to selectively control of the organic working fluid in a conduit connected at least one of a first boiler or a second boiler to the three way valve and a conduit connected to the three way and a turbocharge assist turbine, and a conduit connected to the three way valve and to a condenser.

8. A system as set forth in claim 7 further comprising a conduit connected to the turbocharger assist turbine to the conduit connected to the three way valve and to a condenser.

9. A system as set forth in claim 2 wherein the first boiler is connected to a high pressure EGR loop connected to an engine of the vehicle engine system, and the Organic Rankine Cycle further comprising a second boiler connected to a low pressure EGR loop connected to an engine of the vehicle engine system, and a three way valve up stream of the first boiler constructed and arranged to allow flow of the organic working fluid into the first boiler and a conduit connected to the tree way valve and the second boiler so that at least a portion of the organic working fluid can be caused to selective bypass the first boiler.

10. A method as set forth in claim 1 wherein the working fluid comprises ethanol.

1 1 . A method comprising:

providing an Organic Rankine Cycle having at least a first boiler operatively connected to a vehicle engine system to recover waste heat therefrom, the Organic Rankine Cycle including an organic working fluid, and wherein the Organic Rankine Cycle is operatively connected to a turbocharger system to provide turbocharger assist using energy from the working fluid, the Organic Rankine Cycle comprise an expander downstream of the first boiler, a condenser up downstream of the expander and a pump downstream of the condenser and the first boiler being downstream of the pump, wherein the Organic Rankine Cycle further comprising a first three way valve constructed and arranged to selectively control of the organic working fluid in a conduit connected at least one of a first boiler or a second boiler to the three way valve and a conduit connected to the three way and a turbocharge assist turbine, and a conduit connected to the three way valve and to a condenser, the turbocharge system including a compressor connected to a turbocharger turbine constructed and arranged to turn the compressor;

selectively controlling the first three way valve to allow at least a portion of the working fluid to bypass the expander and flow to the turbocharger assist turbine and turn the compressor.

12. A method as set forth in claim 1 1 wherein the Organic Rankine Cycle further comprising a second boiler connected to a low pressure EGR loop connected to an engine of the vehicle engine system, and a second three way valve up stream of the first boiler constructed and arranged to allow flow of the organic working fluid into the first boiler and a conduit connected to the three way valve and the second boiler so that at least a portion of the organic working fluid can be caused to selective bypass the first boiler;

selectively controlling the second three way valve to cause at least a portion of the organic working fluid to bypass the first boiler and flow into the second boiler.

13. A method as set forth in claim 12 wherein the first boiler is connected to a high pressure EGR loop connected to an engine of the vehicle engine system.

14. A method as set forth in claim 1 1 further comprising determining if the turbo charge system needs assistance in turning the compressor to respond the load demand on the engine and if so performing the act of selectively controlling the first three way valve to allow at least a portion of the working fluid to bypass the expander and flow to the turbocharger assist turbine and turn the compressor.

15. A method as set forth in claim 1 1 wherein the working fluid comprises ethanol.