![Page 1: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/1.jpg)
Electric Turbo Compounding… A Technology Who’s Time Has Come
• Carl T. Vuk
• John Deere Technical Center
![Page 2: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/2.jpg)
OUTLINE • System Architecture • Review of Hardware Elements
• System Analysis • Test Results • Application Recommendations • Conclusions • Future Work • Questions
24 Aug, 2006
![Page 3: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/3.jpg)
Electric Turbo Compounding: • A System That Converts Waste Exhaust Energy
to Shaft Work, using a Turbine, and Couples it Back to the Engine, Electrically
![Page 4: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/4.jpg)
Why Turbo Compounding ? • Today’s Engines Reject 40% of the Fuel’s Energy in the
Exhaust Gas Stream. The Exhaust is an Excellent Source of High Grade Heat, And it’s Free!
• Turbo Compounding Technology is Available and Proven With Mature System Costs in the Order of $50/kW.
• The Technology Provides Power Growth, Improved Fuel Economy, and Reduced Emissions.
24 Aug, 2006
![Page 5: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/5.jpg)
24 Aug, 2006
System Architecture
![Page 6: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/6.jpg)
Turbo Generator
• Converts Exhaust Energy into Shaft Work
• Converts Shaft Work into Electrical Power• Simple Architecture • Very High Efficiency • Known Technology • Cost Effective Design
24 Aug, 2006
![Page 7: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/7.jpg)
Motor Generator
• Generates When Turbo Gen Can Not (Generating Mode) • Couples Turbo Gen Power Back to Engine (Motoring Mode)• Flywheel Mounted for Compact Packaging • Simple Low Cost Machine Using Known Technology • High Efficiency BPM Technology
24 Aug, 2006
![Page 8: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/8.jpg)
Power Electronics
• Controls Turbo Gen Speed and Delivers DC Power• Manages Motor Gen to Regulate BUS Voltage • Very High Efficiency Over Operating Envelope • Cost Effective Components • Liquid Cooled
24 Aug, 2006
![Page 9: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/9.jpg)
Advanced TurboCharger
• High Pressure Turbine • Significantly Upgraded Efficiency • Fixed Geometry Turbine Nozzle Vanes
• Vaned Diffuser (Compressor)
24 Aug, 2006
![Page 10: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/10.jpg)
24 Aug, 2006
Dyno Test Setup Advanced Turbocharger
Power turbine
Generator
![Page 11: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/11.jpg)
Two Stage Architecture
• Independent Control of Turbo Machinery Elements • Modest Pressure Ratios • Interstage After Treatment • Allows for Simple Turbo Machinery • Improved Transient Response
24 Aug, 2006
![Page 12: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/12.jpg)
Electric Coupling • Power Turbine Speed Control Optimization • Efficient Power Recirculation w/o Fluid Coupling
• Packaging Flexibility • Motor Generator Supports Vehicle Electrification
24 Aug, 2006
![Page 13: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/13.jpg)
Variable Geometry Turbines • VG TurboCharger Not Needed to Drive EGR • VG Power Turbine - Option
• Provides Direct Control of Turbo Compounding Output • Increases Part Load & Part Speed Output • Potential Control of Engine Air Flow & Transient Response
• Fixed Geometry Power Turbine – Option • Better Efficiency at Full Load • Reduced System Complexity • Lower Cost
24 Aug, 2006
![Page 14: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/14.jpg)
24 Aug, 2006
Variable Vane Mechanism (Power Turbine)
![Page 15: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/15.jpg)
24 Aug, 2006
Variable Vane Mechanism (Power Turbine)
![Page 16: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/16.jpg)
Motor Generator Optimization • Efficiency Must be High (95%) in Operating Envelope • Packaging is Critical For Common Design and Minimal
Vehicle Disruption • Every Application is Different. Assuming Will Not Produce
Optimal Results
24 Aug, 2006
![Page 17: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/17.jpg)
Engine Test Data (Output Characteristics) TG Power vs. Load and Speed: TG3 w/-20% & -39% NGV, BW VTG, PCU1 - 7Sep05
0 200 400 600 800 1000 1200 1400
Engine Load - Nm
w/ Tier 3 Emissions Injection Timing and EGR Schedules
0
5
10
15
20
25
30
35
40
45
50
55
60
TG P
ower
- kW
e
2300 RPM - TG3 w/-39% NGV - BW VTG 2300 RPM - TG3 w/-20% NGV - BW VTG 2300 RPM - TG3 w/Nom NGV - BW VTG 2100 RPM - TG3 w/-39% NGV - BW VTG 2100 RPM - TG3 w/-20% NGV - BW VTG 2100 RPM - TG3 w/Nom NGV - BW VTG
24 Aug, 2006
![Page 18: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/18.jpg)
Engine Performance Data (Fuel Economy)
Fuel Economy: Combined Engine Shaft + Electric Power Outputs
300 500 700 900 1100 1300
Engine Load - Nm
190
195
200
205
210
215
220
225
230
235
240
245
250
255
260
Com
bine
d SF
C -
g/kW
h
Non-Turbocompound Baseline Engine
Turbocompound Engine
24 Aug, 2006
![Page 19: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/19.jpg)
Application Targets – Turbo Compounding
• High-Duty Cycle Steady State Operation MaximizesBenefit
• High Annual Usage Improves Payback • Vehicle Electrification Helps Justify Added Cost
• Motor/Gen Needed Even w/o TurboCompounding • More Efficient to Use Electrical Power in Vehicle
• Power Growth • Valuable in Some Applications • Allows Smaller Higher Duty Cycle Engines in
Applications Not Needing Power Growth
24 Aug, 2006
![Page 20: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/20.jpg)
24 Aug, 2006
Ideal Applications
Combines
Large Tractors Row Crop Tractors
Trucks
![Page 21: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/21.jpg)
24 Aug, 2006
Tractor Mounted Turbo Generator
![Page 22: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/22.jpg)
24 Aug, 2006
Hardware Integrated in Tractor
![Page 23: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/23.jpg)
24 Aug, 2006
Deere 9L Engine in International Truck
![Page 24: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/24.jpg)
Conclusions: • 20% Power Growth Has Been Demonstrated With Little
Adverse Impact On The Engine. Higher Output is Possible. • Fuel Economy Improvements of 10% Have Been
Demonstrated at Tier 3 Conditions • Turbo Compounding is Compatible With Emissions and
Appears to Provide Benefit • An Electrically Coupled Two Stage Architecture offers
Control, Efficiency, Emissions, and Packaging Benefits. It Also Supports Electrification.
• System Costs Suggest Commercialization Potential
24 Aug, 2006
![Page 25: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/25.jpg)
Future Work • Evaluate Benefits of the Variable Geometry Power Turbine
• Characterize Performance Benefits in Vehicles • Deere Tractor • On-Highway Truck
• Expand Scope to Include Larger Engines • Develop Next Generation Hardware
• Optimize for Tier 4
24 Aug, 2006
![Page 26: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/26.jpg)
Acknowledgements • I would like to thank John Deere, US Department of Energy,
International Truck, and Eaton for support of this program, and for allowing us to share a high level overview of this work.
24 Aug, 2006
![Page 27: A Technology Who’s Time Has Come...Turbo Generator • Converts Exhaust Energy into Shaft Work • Converts Shaft Work into Electrical Power • Simple Architecture • Very High](https://reader034.vdocuments.site/reader034/viewer/2022042212/5eb58f7c3384ff1890395d70/html5/thumbnails/27.jpg)
24 Aug, 2006
Questions ?