Patent Application
20190249595
None.
The present disclosure relates to surge control systems and methods for internal combustion engines, and in particular, a compound boosting system of an internal combustion engine that utilizes a variable valve to adjust the amount of compressed air to the internal combustion engine to increase the power and performance of the internal combustion engine.
Many internal combustion engine systems include boosting devices, such as turbochargers and superchargers, which compress air to increase air flow and thus improve power and performance of an internal combustion engine. However, it is well known that compressors are subject to “surge,” which refers to an unstable condition in which the air pressure downstream of the compressor exceeds the pressure that the compressor can physically maintain. While surge does not typically result in catastrophic damage, it has several undesirable effects including negative air flow, compressor stall, engine noise, etc.
Various systems and methodologies have been developed to combat compressor surge. For example, some systems utilize a dedicated recirculation valve to increase airflow. Known systems and methodologies, however, fail to disclose the use of a multifunctional valve that is operable as both a bypass valve and a recirculation valve to address surge in a compressor.
In one aspect of the present disclosure, an engine system is disclosed that includes an engine, a compound boosting system, and a variable valve. The compound boosting system is configured and dimensioned to compress air flowing into the engine to increase power and performance and includes a first booster and a second booster.
The first booster includes a first compressor having an inlet and an outlet positioned in a flow path of incoming air, a shaft that is connected to the first compressor, and a turbine that is connected to the shaft. The turbine is positioned in a flow path of exhaust created by the engine such that the engine exhaust rotates the turbine to thereby cause rotation of the first compressor, thereby resulting in first stage compression of the incoming air.
The second booster is positioned downstream of the first booster and includes an electrically driven compressor having an inlet and an outlet
The variable valve is positioned between the first booster and the second booster in a flow path of compressed air exiting the first booster. The variable valve is movable between a fully closed position, and one or more open positions. The variable valve is configured, dimensioned, and positioned such that the variable valve is movable from the closed position to one of the open positions when the second booster is running to recirculate air from adjacent the outlet of the second compressor to the inlet of the second compressor to mitigate surge in the second booster.
In certain embodiments, the variable valve may be configured, dimensioned, and positioned such that in the open positions, when the second booster is not running, compressed air exiting the first booster can flow into the engine: (i) through the second booster; and/or (ii) around the second booster.
In certain embodiments, the variable valve may be configured, dimensioned, and positioned such that in the fully closed position, when the second booster is running, compressed air exiting the first booster flows into the second booster for second stage compression before flowing into the engine.
In certain embodiments, the variable valve may be configured, dimensioned, and positioned for movement between a first partially open position and a second partially open position, wherein air flow through the variable valve is greater in the second partially open position.
In certain embodiments, the second booster may further include an electric motor in communication with the second compressor to rotate the second compressor.
In certain embodiments, the second booster may further include a power source in communication with the electric motor, such as a battery.
In certain embodiments, the engine system may further include an intercooler positioned downstream of the first booster and upstream of the second booster.
In certain embodiments, the engine system may further include a controller in communication with the variable valve to move the variable valve between the fully closed position, the fully open position, and the one or more partially open positions.
In certain embodiments, the engine system may further include one or more sensors in communication with the controller that are adapted to collect and transmit data to the controller including information concerning operating conditions the engine system. In such embodiments, the controller may be adapted and programmed to: (i) process the data received from the one or more sensors to determine whether surge has occurred or is likely to occur in the second booster; and (ii) transmit a signal to the variable valve to move the variable valve from the closed position to one of the open positions to facilitate air recirculation from adjacent the outlet of the second compressor to the inlet of the second booster to mitigate surge, or a likelihood of surge, in the second booster.
In another aspect of the present disclosure, an engine system is disclosed that includes an engine, a compound boosting system in communication with the engine, and a variable valve. The compound boosting system includes a turbine-driven booster and an electric booster that is positioned downstream of the turbine-driven booster. The variable valve is multifunctional, and is configured and dimensioned for operation as both a recirculation valve and a bypass valve. More specifically, the variable valve is configured, dimensioned, and positioned such that, when the electric booster is running, the valve can be moved from a closed position to an open position. In the closed position, air flows in a single downstream direction through the electric booster, and in the open position, air flows downstream through the electric booster and upstream through the variable valve such that air is recirculated from adjacent the outlet of the second booster to the inlet of the second booster through the variable valve to mitigate surge, or a likelihood of surge, in the second booster.
In certain embodiments, the variable valve may be movable between a fully closed position and one or more open positions.
In certain embodiments, the variable valve may be configured, dimensioned, and positioned such that in the open positions, when the electric booster is not running, compressed air exiting the turbine-driven booster can flow into the engine: (i) through the electric booster; and/or (ii) around the electric booster.
In certain embodiments, the variable valve may be configured, dimensioned, and positioned such that in the fully closed position, when the electric booster is running, compressed air exiting the turbine-driven booster flows into the electric booster for additional compression before flowing into the engine.
In certain embodiments, the variable valve may be configured, dimensioned, and positioned for movement between a first partially open position and a second partially open position, wherein air flow through the variable valve is greater in the second partially open position.
In certain embodiments, the engine system may further include a controller in communication with the variable valve to move the variable valve between the fully closed position, the fully open position, and the one or more partially open positions.
In certain embodiments, the engine system may further include one or more sensors in communication with the controller that are adapted to collect and transmit data to the controller including information concerning operating conditions the engine system. In such embodiments, the controller may be adapted and programmed to: (i) process the data received from the one or more sensors to determine whether surge has occurred or is likely to occur in the second booster; and (ii)transmit a signal to the variable valve to move the variable valve from the closed position to open position to facilitate air recirculation from adjacent the outlet of the electric booster to the inlet of the electric booster through the variable valve.
In another aspect of the present disclosure, a method is disclosed for mitigating surge in an electric booster positioned downstream of a turbine-driven booster. The method includes directing air flow into the turbine-driven booster for first stage compression, (i) closing a variable valve positioned downstream of the turbine-driven booster during operation of the electric booster; or (ii) maintaining the variable valve in a closed position such that air compressed by the turbine-driven booster flows into the electric booster for second stage compression, collecting data using one or more sensors to monitor surge conditions in the electric booster, receiving one or more signals from the one or more sensors in a controller to determine whether surge has occurred or is likely to occur in the electric booster, and if it is determined that surge has occurred or is likely to occur in the electric booster, transmitting a signal from the controller to the variable valve to move the valve from the closed position to an open position that air is recirculated from adjacent an outlet of the electric booster to an inlet of the electric booster through the variable valve to increase air flow into the inlet of the electric booster.
In certain embodiments, the method may further include changing the position of the variable valve from a first open position to a second open position to change air flow through the variable valve.
In certain embodiments, the method may further include closing the variable valve after a determination is made by the controller that surge has been successfully addressed.
The disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings. It is emphasized that, according to common practice, the various features of the drawings are not to-scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity.
Various embodiments of the present disclosure will now be described in detail with reference to the figures, wherein like references numerals identify similar or identical elements. With reference now to
In the embodiment of the internal combustion engine system 10 seen in
The first booster 100 receives a flow of incoming air and is positioned upstream of the second booster 200. The first booster 100 includes a compressor 102 having respective inlets and outlets 104, 106, a turbine 108, and a shaft 110 that interconnects the compressor 102 and the turbine 108. The turbine 108 is positioned downstream of the internal combustion engine 12 in the path of exhaust gases produced by the engine 12 such that as the engine 12 operates, the exhaust gases produced flow into and spin the turbine 108. The rotational energy of the turbine 108 is communicated to the compressor 102 by the shaft 110 to rotate the compressor 102 thereby compressing the incoming flow of air after passing through an air filter 112.
The second booster 200 includes a compressor 202 having respective inlets and outlets 204, 206, and may operate concurrently with the first booster 100. The second booster 200 is driven by an electric motor 208, which may be powered in any suitable manner, such as by an on-board energy storage device, e.g., a battery 210, a generator, or a combination thereof. In certain embodiments, such as that illustrated in
With continued reference to
The ability to reposition the valve 300 between a plurality of open position(s) allows air flow through the valve 300 to be regulated. More specifically, air flow can be progressively increased or decreased to augment or reduce the amount of air flowing through the valve 300, for example, based upon desired performance of the engine 12 or surge conditions, as discussed below.
Under certain operating conditions, air flow through the second booster 200 may be reduced, potentially resulting in surge conditions that can degrade performance of the compressor 202, and consequently, the engine 12. Such conditions typically occur during high power/low flow operation, such as, for example, during a hard acceleration or during operation of the engine 12 in an improperly high gear in the transmission (not shown). During surge conditions, due to the low flow of air into the compressor 202, pressure at the outlet 206 exceeds pressure at the inlet 204 to such an extent that a reversal of air flow through the compressor 202 can occur in which air attempts to flows “upstream” through the compressor 202 from the area of higher pressure (at the outlet 206) to the area of lower pressure (at the inlet 204). To mitigate the negative impact of such a flow reversal, the valve 300 can be moved into one of the open positions in order to redirect and recirculate the air flowing “upstream” into the inlet 204 of the compressor 202. More specifically, by opening the valve 300, an alternate path is created that allows air to be recirculated for flow into the inlet 204 (in the direction indicated by arrow 4) to increase pressure at the inlet 204. By increasing pressure at the inlet 204, the pressure differential at the outlet 206 and the inlet 204 can be reduced, thereby mitigate surge. During such operation, as the valve 300 moves from the closed position to one of the open positions, the role played by the valve 300 thus changes from one of bypass to one of recirculation.
To monitor, evaluate, and combat surge conditions, the engine system 10 may include a controller 500 and one or more sensors 600. The controller 500 is adapted and programmed to receive data from the sensor(s) 600, process the data, and transmit signals to carry out various tasks, such as one or more routines programmed into the logic of the controller 500 to perform certain functions. For example, based on the data collected by the sensor(s) 600 and the calculations performed by the controller 500, the controller 500 may vary operation of the engine 12, activate or deactivate the second booster 200, transmit a signal to vary the position of the valve 300 between the closed position and one of the open positions, thereby altering the flow of air through the second booster 200, etc.
The sensor(s) 600 included in the internal combustion engine system 10 may include several varieties and may be positioned in various locations to collect data pertaining to the operating conditions of the internal combustion engine system 10. For example, the internal combustion engine system 10 may include one or more sensors 600 to measure or estimate temperature at the respective inlets 104, 204 of the compressors 106, 206, to measure the pressure at various locations, such as at the respective outlets 106, 206 of the compressors 102, 202, to determine the air-fuel ratio in the engine 12, to measure the levels of humidity, engine speed, fueling, load, etc.
After receiving data collected by the sensor(s) 600, the controller 500 can process the data to vary operation of the internal combustion engine system 10. For example, in one set of operating conditions, as the engine 12 runs, the exhaust gases build up and ultimately act on the turbine 108 of the first booster 100. However, in the interval of time between the initiation of engine operation and the initiation of spin in the turbine 108, there may be a delay in the communication of energy to the compressor 102 of the first booster 100, commonly referred to a “turbo lag.” To compensate for this delay and reduce or minimize the impact upon performance of the internal combustion engine system 10, the controller 500 may transmit a signal to actuate the second booster 200 to increase the pressure and compression of air entering the engine 12 while the compressor 102 comes up to speed based upon the pressure measured by a sensor 600 at the outlet 106 of the compressor 102 of the first booster 100. During such operation, the controller 500 may close the valve 300 such that air is directed into the second booster 200 prior to entering the engine 12. However, after the turbine 108 of the first booster 100 has achieved sufficient rotational speed in order to generate adequate compression by the compressor 102, as measured by a sensor 600 at the outlet 106 of the compressor 102, the controller 500 may either deactivate the second booster 200 and open the valve 300 such that air compressed by the first booster 100 passes directly into the engine 12, or alternatively, the controller 500 may maintain the closed position of the valve 300 such that air exiting the compressor 102 of the first booster 100 undergoes a second stage of compression by the booster 206 to further increase the power produced by the engine 12.
During operation of the engine 12, the position of the valve 300 can be continually varied by the controller 500 depending on the operating conditions measured by the sensor(s) 600. When the controller 500 recognizes surge, or conditions that may result in surge, the controller 500 can vary the exact position of the valve 300, for example, by moving the valve 300 from the closed position to one of the open positions, or by increasing the opening of the valve, in order to control air flow into the second booster 200 based on data collected by the sensors 600 relating to compressor ratio, compressor flow rate, pressure differentials, etc. When pressure measured at the outlet 206 of the second booster 200 exceeds pressure measured at the inlet 204 by a certain amount or percentage, such as a ratio within the range of 1.25 to 3 or more, the controller 500 can open the valve 300 to permit the recirculation of air into the inlet 204 to reduce the pressure differential, as discussed above. When surge or surge conditions are not identified by the controller 500, however, such as when pressures at the outlet 206 and the inlet 204 are within a certain tolerance, for example, the valve 300 may remain closed such that air is continuously drawn into the second booster 200. The controller 500 may thus be programmed to vary functionality of the valve 300 between bypass and recirculation operations.
Dependent upon the particular operating conditions, it is envisioned that the controller 500 may open the valve 300 such that air, or a portion of the air, bypasses the second booster 200 to thereby limit compression in order to achieve a particular output by the engine 12. It is also envisioned that the controller 500 may close the valve 300 to maximize air flow into the second booster 200 to increase compression and power generated by the engine 12.
With reference to
At step “A”, various operating conditions are estimated and/or measured by the sensor(s) 600, such as the charge in the battery 210, pressure at the inlet 204 of the compressor 202, pressure at the outlet 206 of the compressor 202, etc. Data collected by the sensor(s) 600 is then communicated to the controller 500 at step “B”, and the controller 500 evaluates whether surge is either likely to occur, or whether the compressor 202 is presently experiencing surge at step “C”. If it is determined by the controller 500 that the compressor 202 is not experiencing surge or that the compressor 202 is not likely to experience surge, the position of the valve 300 can be maintained in (or returned to) the fully closed position at step “E”, and the routine then repeats steps “A”-“C” to continually monitor the conditions of the engine 12. However, if it is determined by the controller 500 at step “C” that the compressor 202 is either presently experiencing surge or that the compressor 202 is likely to experience surge, the controller 500 can transmit a signal to the valve 300 at step “D” to transition the valve 300 from the fully closed position to one of the partially open conditions. Following repositioning of the valve 300, the controller 500 and the sensors 600 may continually monitor the conditions of the engine 12 by repeating steps “A”-“C” to determine whether surge was successfully addressed by opening the valve 300. If it is determined that surge either has not been successfully addressed, based upon data collected by the sensor(s) 600 subsequent to initial opening of the valve 300, the controller 500 can either maintain the open position of the valve 300 or open the valve 300 further at step “D” to increase air flow into the compressor 202. Steps “A”-“C” can then be repeated to collect and process additional data until such time that the controller 500 determines that surge in the compressor 202 of the second booster 200 has been successfully addressed.
Persons skilled in the art will understand that the various embodiments of the disclosure described herein, and shown in the accompanying figures, constitute non-limiting examples, and that additional components and features may be added to any of the embodiments discussed herein above without departing from the scope of the present disclosure. Additionally, persons skilled in the art will understand that the elements and features shown or described in connection with one embodiment may be combined with those of another embodiment without departing from the scope of the present disclosure, and will appreciate further features and advantages of the presently disclosed subject matter based on the description provided. Variations, combinations, and/or modifications to any of the embodiments and/or features of the embodiments described herein within the abilities of a person having ordinary skill in the art are also within the scope of the disclosure, as are alternative embodiments that may result from combining, integrating, and/or omitting features from any of the disclosed embodiments. For example, in alternate embodiments, the inclusion, order, and arrangement of the components discussed herein may be varied. For instance, in alternate embodiments, the second (electric) booster 200 may be located upstream of the first booster 100, the location of the intercooler 400 may be varied, or the intercooler 400 and/or the first booster 100 may be eliminated altogether.
