Download - Turbo Compound
JohnDeere
CREATING THE FUTUREAdvanced Engineering
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Turbo CompoundingA Technology Who’s Time Has Come
Turbo CompoundingA Technology Who’s Time Has Come
25 Aug, 2005 Carl T. Vuk
John Deere Moline Technical Center
JohnDeere
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25 August, 2005
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OUTLINEOUTLINEHistoryRate LimitersEnvironmental FactorsElectric Turbo CompoundingSystem ArchitectureDrivers AnalysisTestingSummary
JohnDeere
CREATING THE FUTUREAdvanced Engineering
25 August, 2005
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Turbo Compounding HistoryTurbo Compounding History1953 Douglas DC-7 (Wright 3350 TC)1954 Napier Nomad (12 Cyl Diesel 2-stroke)1968 Mitsubishi 10ZF (V10 2-stroke Diesel)1981 Cummins NH1983 Cummins V903 (Military Application)1986 Cat 3406 & 11.3L1988 Hino 8.82L1990 DAF1991 Scania 11L (Current Production)1998 Cat 15L (21st Century Truck)2002 Isuzu Ceramic IDI (Experimental)2002 Volvo (Current Production)
JohnDeere
CREATING THE FUTUREAdvanced Engineering
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Technology Delivery ProcessNapier NomadCirca 1955
Napier NomadCirca 1955
JohnDeere
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Technology Delivery ProcessTwo-Stage Mechanically Coupled System
Two-Stage Mechanically Coupled System
JohnDeere
CREATING THE FUTUREAdvanced Engineering
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Technology LimitersTechnology Limiters
System ComplexityHigh Ratio Gear TrainsTorsional CouplersImpact on Turbocharger and EngineMachine Placement
Control IssuesCosts
JohnDeere
CREATING THE FUTUREAdvanced Engineering
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Factors Favoring TCFactors Favoring TC
Increasing Fuel CostsAvailability of Low Cost ControlsAvailability of Cost Effective Power Electronics (Automotive Hybridization)EGR Requirements for NOx ControlHigh Pressure Ratio VG Turbos
JohnDeere
CREATING THE FUTUREAdvanced Engineering
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Technology Delivery ProcessElectric Turbo CompoundingElectric Turbo Compounding
Simple Architectures PossibleFlexible PlacementIsolated Coupling
Integrated Electronic ControlHigh EfficiencyModest Cost
JohnDeere
CREATING THE FUTUREAdvanced Engineering
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Technology Delivery ProcessTurboCompounding Drivers
TurboCompounding Drivers
Improved Fuel Economy - 10+%Increased Power Density - 20+%Emissions & After Treatment BenefitsHigh Exhaust Pressure Requirement – EGRMaturation of Electrification Technology
JohnDeere
CREATING THE FUTUREAdvanced Engineering
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Emissions ImpactEmissions Impact
Increased Output Directly Impacts Specific EmissionsPower Turbine Reduces Net Impact of Retarded Injection TimingImproved Transient Response Lowers EmissionsElectrical Output Can Power Emissions Control Devices
JohnDeere
CREATING THE FUTUREAdvanced Engineering
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Technology Delivery ProcessPower Density Growth Enablers
Power Density Growth Enablers
Turbo Chargers (1970 – 1990)After Cooling (1975 – 2005)High Performance Pistons (1985 – 2005)Turbo Compounding (2008 - ….)
JohnDeere
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TC System SchematicElectrically Coupled Deere System
JohnDeere
CREATING THE FUTUREAdvanced Engineering
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Technology Delivery ProcessTurbo Generatoron Gas Stand
Turbo Generatoron Gas Stand
JohnDeere
CREATING THE FUTUREAdvanced Engineering
25 August, 2005
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AnalysisAnalysis
JohnDeere
CREATING THE FUTUREAdvanced Engineering
25 August, 2005
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Turbocharger AssemblyTurbocharger Assembly
JohnDeere
CREATING THE FUTUREAdvanced Engineering
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Technology Delivery ProcessAdvanced TurboCharger
Advanced TurboCharger
JohnDeere
CREATING THE FUTUREAdvanced Engineering
25 August, 2005
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Power ElectronicsPower Electronics
JohnDeere
CREATING THE FUTUREAdvanced Engineering
25 August, 2005
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Engine TestingEngine Testing
JohnDeere
CREATING THE FUTUREAdvanced Engineering
25 August, 2005
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Technology Delivery Process
Engine TestingEngine Testing
JohnDeere
CREATING THE FUTUREAdvanced Engineering
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System Parameters
50 kW Turbo Generator340V DC OutputWastegate Control For Overspeed Protection50 kW Motor/GeneratorNo Energy StorageIntegrated Control Engine/Turbo GeneratorAdvanced High Pressure Ratio Turbocharger
JohnDeere
CREATING THE FUTUREAdvanced Engineering
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Efficiency TargetsEfficiency Targets
Power Turbine 85%Turbo Generator w/Controller 95%Turbocharger Compressor 78%Turbocharger Turbine 85%Motor/Generator w/Controller 95%Engine w/TurboCompounding 46%
JohnDeere
CREATING THE FUTUREAdvanced Engineering
25 August, 2005
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Turbocompound Effect On Performance
6
7
8
9
10
11
12
0 5 10 15 20 25 30Power Turbine Power As A Percentage Of Total System Power [%]
Effic
ienc
y Im
prov
emen
t [%
]
AFR = 30
AFR = 26
AFR = 23
WAVE Performance PredictionsWAVE Performance Predictions
JohnDeere
CREATING THE FUTUREAdvanced Engineering
25 August, 2005
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Engine Test DataEngine Test Data
TurboGenerator Power vs. Engine Speed and Load
0
5
10
15
20
25
30
35
40
45
50
55
60
0 20 40 60 80 100Engine Load (%)
TG P
ower
- kW
e
2300 RPM2100 RPM1900 RPM
JohnDeere
CREATING THE FUTUREAdvanced Engineering
25 August, 2005
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Technology Delivery ProcessApplication Selection Criteria
Application Selection Criteria
Steady-State High-Duty Cycle OperationHigh Annual UsagePower Growth RequirementVehicle Electrification Benefits
JohnDeere
CREATING THE FUTUREAdvanced Engineering
25 August, 2005
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Potential Applications
Combine
9000 Tractor 8000 Tractor
Truck
JohnDeere
CREATING THE FUTUREAdvanced Engineering
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DoE Program FocusDoE Program Focus
Define Application ScopeDevelop and Evaluate Second Generation HardwareIntegrate Turbo Compounding With Engine for Optimal Performance and Emissions
JohnDeere
CREATING THE FUTUREAdvanced Engineering
25 August, 2005
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SummarySummary
Proven TechnologySignificant, Economy, Power, and Emissions BenefitsMust be Integrated With Emissions Strategies and Vehicle ElectrificationBenefits in Specific Applications to be Defined
JohnDeere
CREATING THE FUTUREAdvanced Engineering
25 August, 2005
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AcknowledgmentsAcknowledgments
FundingJohn Deere Tech CouncilDOE
Engine Performance TestingTodd Whiting
JohnDeere
CREATING THE FUTUREAdvanced Engineering
25 August, 2005
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Questions ?Questions ?