Turbocharger with Electrically Coupled Fully Variable Turbo-Compound Capability and Method of Controlling the Same

Patent metadata

Field	Value
Publication number	US-2016017793-A1
Application number	US-201514804535-A
Country	US
Kind code	A1
Filing date	Jul 21, 2015
Priority date	Jul 21, 2014
Publication date	Jan 21, 2016
Grant date	—

Abstract

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.

First claim

What is claimed is:

1 . A turbocharger apparatus of an internal combustion engine comprising:
a turbine; a compressor; an electric machine 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; and a planetary gearset connecting said turbine, said compressor, and said electric machine.

2 . The turbocharger apparatus as set forth in claim 1 further comprising:
an electricity source; and
an 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 planetary gearset includes:
a sun gear rotatably coupled with said turbine;
a ring gear that is disposed circumferentially about and radially spaced from said sun gear and that is rotatably coupled with said electric machine; and
at least one planet gear disposed radially between and in meshing engagement with said sun gear and said ring gear, said at least one planet gear being carried on a carrier that is rotatably coupled with said compressor.

7 . The turbocharger apparatus as set forth in claim 6 further comprising:
an auxiliary gear rotatably coupled to and carried on a rotating shaft of said electric machine; and
a 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.

8 . 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.

9 . 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.

10 . 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.

11 . A turbocharger apparatus of an internal combustion engine comprising:
a turbine; a compressor; 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 and 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; and a planetary gearset connecting said turbine, said compressor, and said second electric machine that varies rotational speeds of said turbine, said compressor, and 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.

12 . The turbocharger apparatus as set forth in claim 11 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.

13 . The turbocharger apparatus as set forth in claim 12 further comprising:
an electrical power coupling electrically connected to said first electric machine and said second electric machine that transfers electricity therebetween.

14 . The turbocharger apparatus as set forth in claim 11 wherein said planetary gearset includes:
a sun gear rotatably coupled with said turbine;
a ring gear that is disposed circumferentially about and radially spaced from said sun gear and that is rotatably coupled with said second electric machine; and
at least one planet gear disposed radially between and in meshing engagement with said sun gear and said ring gear, said at least one planet gear being carried on a carrier that is rotatably coupled with said compressor.

15 . The turbocharger apparatus as set forth in claim 14 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.

16 . The turbocharger apparatus as set forth in claim 14 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.

17 . The turbocharger apparatus as set forth in claim 14 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.

18 . The turbocharger apparatus as set forth in claim 11 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 ma

Assignees

• Avl Powertrain Engineering Inc

Inventors

• Johnson Gustav R

Classifications

• F02B39/04

  Mechanical drives; Variable-gear-ratio drives (non-mechanical pump drives having variable gear ratio F02B39/08) · CPC title

• F02B39/10 Primary

  electric · CPC title

• Y02T10/12

  Improving ICE efficiencies · CPC title

• F02B41/10

  in exhaust turbines (use of exhaust turbines for charging F02B37/00) · CPC title

• F02B37/10

  at least one pump being alternatively {or simultaneously} driven by exhaust and other drive, {e.g. by pressurised fluid from a reservoir or an engine-driven pump} · CPC title