Turbocharger with electrically coupled fully variable turbo-compound capability and method of controlling the same
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
F02B-033/44
B60K-006/20
F02B-033/00
F02B-063/04
F02D-029/06
F01D-015/10
F16H-003/44
F16H-047/04
F16H-047/08
F02B-039/10
F02B-039/04
F02B-037/10
F02B-041/10
출원번호
US-0804535
(2015-07-21)
등록번호
US-9752496
(2017-09-05)
발명자
/ 주소
Johnson, Gustav R.
출원인 / 주소
AVL POWERTRAIN ENGINEERING, INC.
대리인 / 주소
Harness, Dickey & Pierce, P.L.C.
인용정보
피인용 횟수 :
0인용 특허 :
20
초록▼
A turbocharger apparatus of an internal combustion engine and method of controlling the same is provided with electrically coupled fully variable turbo-compound capability. The turbocharger includes an exhaust gas turbine and an intake air compressor. A first electric machine coupled to the engine g
A turbocharger apparatus of an internal combustion engine and method of controlling the same is provided with electrically coupled fully variable turbo-compound capability. The turbocharger includes an exhaust gas turbine and an intake air compressor. A first electric machine coupled to the engine generates electricity and adds power to an output shaft of the engine depending on electricity flow to and from the first electric machine. A second electric machine coupled to the turbine and/or the compressor generates electricity and drives the turbine and/or the compressor depending on electricity flow between the first and the second electric machines. A planetary gearset connects the turbine, the compressor, and the second electric machine, and varies rotational speeds of the turbine, the compressor, and the second electric machine depending on electricity flow between the first and second electric machines to maximize efficiency and power of the engine.
대표청구항▼
1. A turbocharger apparatus of an internal combustion engine comprising: a turbine mounted on a turbine shaft;a compressor mounted on a compressor shaft;an electric machine with a rotating shaft rotatably coupled to at least one of said turbine and said compressor that generates electricity in an el
1. A turbocharger apparatus of an internal combustion engine comprising: a turbine mounted on a turbine shaft;a compressor mounted on a compressor shaft;an electric machine with a rotating shaft rotatably coupled to at least one of said turbine and said compressor that generates electricity in an electricity generating state where electricity flows from said electric machine and that rotationally drives at least one of said turbine and said compressor in an electricity consuming state where electricity flows to said electric machine;a planetary gearset; wherein said planetary gearset further includes: a sun gear rotatably coupled to said turbine shaft;at least one planet gear rotatably coupled to said compressor shaft; anda ring gear rotatable coupled to said rotating shaft of said electric machinean auxiliary gear rotatably coupled to and carried on said rotating shaft of said electric machine; anda transfer gear rotatably coupled to and extending from said ring gear that is meshingly engaged with said auxiliary gear such that said auxiliary gear and said transfer gear rotatable couple said ring gear and said electric machine. 2. The turbocharger apparatus as set forth in claim 1 further comprising: an electricity source; andan electrical power coupling electrically connected to said electric machine and said electricity source that transports electricity therebetween. 3. The turbocharger apparatus as set forth in claim 2 wherein said electricity source is another electric machine that is rotatably coupled to the internal combustion engine. 4. The turbocharger apparatus as set forth in claim 2 wherein said electricity source is a battery that is configured to store electricity. 5. The turbocharger apparatus as set forth in claim 2 further comprising: a controller in electrical communication with said electric machine that controls electricity flow to and from said electric machine. 6. The turbocharger apparatus as set forth in claim 1 wherein said ring gear is disposed circumferentially about and radially spaced from said sun gear and is coupled to said rotating shaft of said electric machine; andwherein said at least one planet gear is disposed radially between and in meshing engagement with said sun gear and said ring gear, and is carried on a carrier that is rotatably coupled with said compressor shaft. 7. The turbocharger apparatus as set forth in claim 6 wherein said planetary gearset provides a first ratio where said electric machine holds said ring gear fixed in place such that all mechanical power generated by said turbine is transferred through said planetary gearset to said compressor via said sun gear, said at least one planet gear, and said carrier. 8. The turbocharger apparatus as set forth in claim 6 wherein said planetary gearset provides a second ratio where said electric machine rotates said ring gear at a rotational speed that equals a rotational speed of said sun gear and said turbine such that excess mechanical power generated by said turbine is used by said electric machine for electricity generation. 9. The turbocharger apparatus as set forth in claim 6 wherein said planetary gearset provides a third ratio where said electric machine rotates said ring gear at a rotational speed that exceeds a rotational speed of said sun gear and said turbine such that said electric machine supplies additional rotational energy to said compressor shaft via said ring gear, said at least one planet gear, and said carrier. 10. A turbocharger apparatus of an internal combustion engine comprising: a turbine mounted on a turbine shaft;a compressor mounted on a compressor shaft;a first electric machine rotatably coupled to the internal combustion engine that generates electricity in an electricity generating state where electricity flows from said first electric machine and that adds rotational power to the internal combustion engine in an electricity consuming state where electricity flows to said first electric machine;a second electric machine electrically connected to said first electric machine, said second electric machine having a rotating shaft that is rotatably coupled to at least one of said turbine and said compressor that generates electricity in an electricity generating state where electricity flows from said second electric machine and that rotationally drives at least one of said turbine and said compressor in an electricity consuming state where electricity flows to said second electric machine;a planetary gearset; wherein said planetary gearset further includes: a sun gear rotatably coupled to said turbine shaft;at least one planet gear rotatably coupled to said compressor shaft; anda ring gear rotatably coupled to said rotating shaft of said second electric machine;wherein said planetary gearset varies rotational speeds of said turbine shaft, said compressor shaft, and said rotating shaft of said second electric machine with respect to one another in response to electricity flow to and from said second electric machine in order to maximize efficiency and power of the internal combustion engine;an auxiliary gear rotatably coupled to and carried on said rotating shaft of said electric machine; anda transfer gear rotatably coupled to and extending from said ring gear that is meshingly engaged with said auxiliary gear such that said auxiliary gear and said transfer gear rotatably couple said ring gear and said electric machine. 11. The turbocharger apparatus as set forth in claim 10 further comprising: a controller in electrical communication with said first electric machine and said second electric machine that controls electricity flow to and from said first electric machine and said second electric machine by adjusting an electrical load applied to each of said first electric machine and said second electric machine. 12. The turbocharger apparatus as set forth in claim 11 further comprising: an electrical power coupling electrically connected to said first electric machine and said second electric machine that transfers electricity therebetween. 13. The turbocharger apparatus as set forth in claim 10 wherein said ring gear is disposed circumferentially about and radially spaced from said sun gear and is coupled to said rotating shaft of said second electric machine; andwherein said at least one planet gear is disposed radially between and in meshing engagement with said sun gear and said ring gear, and is carried on a carrier that is rotatably coupled with said compressor shaft. 14. The turbocharger apparatus as set forth in claim 13 wherein said planetary gearset provides a first ratio where said second electric machine holds said ring gear fixed in place such that all mechanical power generated by said turbine is transferred through said planetary gearset to said compressor via said sun gear, said at least one planet gear, and said carrier. 15. The turbocharger apparatus as set forth in claim 13 wherein said planetary gearset provides a second ratio where said second electric machine rotates said ring gear at a rotational speed that equals a rotational speed of said sun gear and said turbine such that excess mechanical power generated by said turbine is used by said second electric machine for electricity generation. 16. The turbocharger apparatus as set forth in claim 13 wherein said planetary gearset provides a third ratio where said second electric machine rotates said ring gear at a rotational speed that exceeds a rotational speed of said sun gear and said turbine such that said second electric machine supplies additional rotational energy to said compressor shaft via said ring gear, said at least one planet gear, and said carrier. 17. The turbocharger apparatus as set forth in claim 10 wherein said first electric machine includes a first stator and a first rotor rotatably coupled to an engine primary shaft of the internal combustion engine such that said first rotor rotates with respect to said first stator to generate electricity when said first electric machine is in said electricity generating state and such that said first rotor rotationally drives the engine primary shaft when said first electric machine is in said electricity consuming state. 18. The turbocharger apparatus as set forth in claim 17 wherein said second electric machine includes a second stator and a second rotor rotatably coupled to at least one of said turbine and said compressor through said planetary gearset such that said second rotor rotates with respect to said second stator to generate electricity when said second electric machine is in said electricity generating state and such that said second rotor rotationally drives at least one of said turbine and said compressor when said second electric machine is in said electricity consuming state. 19. The turbocharger apparatus as set forth in claim 10 further comprising: a turbocharger housing defining an exhaust passage that transports exhaust gases away from the internal combustion engine and an intake passage that transports intake air towards the internal combustion engine, wherein said turbine is at least partially disposed within said exhaust passage of said turbocharger housing and includes and a plurality of turbine vanes rotatably coupled with said turbine shaft that are propelled by the exhaust gases flowing through said exhaust passage to rotationally drive said turbine shaft, andwherein said compressor is at least partially disposed within said intake passage of said turbocharger housing and includes and a plurality of compressor vanes rotatably coupled with said compressor shaft that increase the intake air flow through said intake passage in response to rotation of said compressor shaft. 20. The turbocharger apparatus as set forth in claim 10 wherein said compressor shaft is separate from and not directly connected to said turbine shaft. 21. The turbocharger apparatus as set forth in claim 20 wherein said turbine shaft and said compressor shaft are connected to one another through only said planetary gearset. 22. A method of controlling a turbocharger apparatus having a turbine, a compressor, a planetary gearset having a sun gear, at least one planet gear, and a ring gear, a first electric machine, a second electric machine, an auxiliary gear rotatably coupled to and carried on a rotating shaft of said second electric machine, and a transfer gear rotatably coupled to and extending from said ring gear being meshingly engaged with said auxiliary gear such that said auxiliary gear and said transfer gear rotatably couple said ring gear and said second electric machine, the method comprising the steps of: driving the turbine with exhaust gas flow from an internal combustion engine, the turbine generating mechanical power in response to being driven by the exhaust gas flow;transferring all of the mechanical power generated by the turbine through the planetary gearset to the compressor during a first operating mode where only the turbine drives the compressor;driving the first electric machine with the internal combustion engine, the first electric machine generating electricity in response to being driven by the internal combustion engine;supplying the electricity generated by the first electric machine to the second electric machine to drive the second electric machine; andtransferring the mechanical power produced by the turbine and the second electric machine through the planetary gearset to the compressor during a second operating mode where both the turbine and the second electric machine drive the compressor. 23. The method set forth in claim 22 further comprising the steps of: transferring some of the mechanical power produced by the turbine through the planetary gearset to the compressor and some of the mechanical power produced by the turbine through the planetary gearset to the second electric machine during a third operating mode, where the turbine drives both the compressor and the second electric machine, the second electric machine generating electricity in response to being driven by the turbine;supplying the electricity generated by the second electric machine to the first electric machine to drive the first electric machine; andtransferring the mechanical power produced by the first electric machine to the internal combustion engine to increase rotational power of the internal combustion engine. 24. The method set forth in claim 23 wherein, during the third operating mode, the turbine drives the sun gear of the planetary gearset at a rotational speed,the sun gear drives the at least one planet gear of the planetary gearset,the at least one planet gear drives the ring gear of the planetary gearset and the compressor,the ring gear drives the second electric machine, andthe second electric machine limits a rotational speed of the ring gear to the rotational speed of the sun gear such that any excess mechanical power generated by the turbine is transferred to the second electric machine via the ring gear for electricity generation. 25. The method set forth in claim 23 wherein the third operating mode is performed when intake air flow to the internal combustion engine is oversupplied. 26. The method set forth in claim 22 wherein, during the first operating mode, the turbine drives the sun gear of the planetary gearset,the sun gear drives the at least one planet gear of the planetary gearset,the at least one planet gear drives the compressor, andthe second electric machine prevents rotation of the ring gear relative to the sun gear such that all of the mechanical power generated by the turbine is transferred to the compressor. 27. The method set forth in claim 22 wherein, during the second operating mode, the turbine drives the sun gear of the planetary gearset at a rotational speed,the sun gear drives the at least one planet gear of the planetary gearset,the at least one planet gear drives the ring gear of the planetary gearset and the compressor, andthe second electric machine drives the ring gear at a rotational speed that exceeds the rotational speed of the sun gear such that the second electric motor increases a rotational speed of the ring gear, the at least one planet gear, and the compressor. 28. The method set forth in claim 22 wherein the first operating mode is performed when intake air flow to the internal combustion engine meets but does not exceed engine airflow requirements. 29. The method set forth in claim 22 wherein the second operating mode is performed when intake air flow to the internal combustion engine is undersupplied.
B��ttcher,Michael; Enderle,Christian; Hufendiek,Jochen; Wunderlich,Klaus, Internal combustion engine comprising a mechanical charger and a turbo-compound.
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