EXTERNAL COMBUSTION ENGINE SERIES HYBRID ELECTRIC DRIVETRAIN
20210179060 · 2021-06-17
Inventors
Cpc classification
F01N5/025
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B60W10/08
PERFORMING OPERATIONS; TRANSPORTING
B60W10/30
PERFORMING OPERATIONS; TRANSPORTING
F01N13/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B60K6/26
PERFORMING OPERATIONS; TRANSPORTING
B60W20/10
PERFORMING OPERATIONS; TRANSPORTING
B60W10/06
PERFORMING OPERATIONS; TRANSPORTING
B60W10/18
PERFORMING OPERATIONS; TRANSPORTING
B60K6/36
PERFORMING OPERATIONS; TRANSPORTING
B60K6/24
PERFORMING OPERATIONS; TRANSPORTING
B60K6/28
PERFORMING OPERATIONS; TRANSPORTING
B60R16/03
PERFORMING OPERATIONS; TRANSPORTING
Y02T10/62
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
B60W20/10
PERFORMING OPERATIONS; TRANSPORTING
B60K6/24
PERFORMING OPERATIONS; TRANSPORTING
B60K6/26
PERFORMING OPERATIONS; TRANSPORTING
B60K6/28
PERFORMING OPERATIONS; TRANSPORTING
B60K6/36
PERFORMING OPERATIONS; TRANSPORTING
B60R16/023
PERFORMING OPERATIONS; TRANSPORTING
B60R16/03
PERFORMING OPERATIONS; TRANSPORTING
B60W10/06
PERFORMING OPERATIONS; TRANSPORTING
B60W10/08
PERFORMING OPERATIONS; TRANSPORTING
B60W10/18
PERFORMING OPERATIONS; TRANSPORTING
B60W10/30
PERFORMING OPERATIONS; TRANSPORTING
F01N13/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A vehicle is provided which includes an engine; an electric motor; a drivetrain driven by said engine and said electric motor, said drivetrain including a rotatable shaft; a generator which is attached to said rotatable shaft, and which generates electrical energy in response to the rotation of said shaft; an energy recovery system; and an electrical energy storage system.
Claims
1. A vehicle, comprising: an engine equipped with at least one combustion chamber which receives a mixture of fuel and air that undergoes combustion in the at least one combustion chamber in accordance with an ignition sequence; a computerized controller which is equipped with a tangible, non-transient medium and which controls the ignition sequence in accordance with an algorithm recorded in said medium; a temperature sensor which is disposed in said engine and which is in communication with said controller, wherein said controller maintains the engine in an inactive state until the temperature sensed by said temperature sensor exceeds a predetermined threshold value; an electric motor; a drivetrain driven by said engine and said electric motor, said drivetrain including a rotatable shaft; a generator which is attached to said rotatable shaft, and which generates electrical energy in response to the rotation of said shaft; an energy recovery system; and an electrical energy storage system.
2. (canceled)
3. The vehicle of claim 1, wherein said engine is based on an external combustion cycle selected from the group consisting of Stirling Cycles, Rankine Cycles, Ericsson Cycles, Brayton Cycles and Kalina Cycles.
4. The vehicle of claim 1, wherein said engine includes a bladeless turbine which produces mechanical energy by means of the Boundary Layer Effect.
5. The vehicle of claim 1, wherein said energy recovery system comprises a thermopile array employing the Seebeck Effect, and wherein said thermopile array is in electrical contact with said electrical storage system.
6. (canceled)
7. The vehicle of claim 5, wherein said energy recovery system further comprises a dynamic braking system which utilizes said electric motor as a generator when said dynamic braking system is engaged, and wherein said thermopile array extracts heat from exhaust gases generated by said engine and converts the extracted heat into electrical energy by way of the Seebek effect.
8. The vehicle of claim 1, further comprising: at least one electrical device selected from the group consisting of current regulators, insulated gate bipolar transistors and solid state switching devices; a plurality of electrical systems; and a controller which controls said electric motor in accordance with an algorithm; wherein electrical energy generated by said generator is routed through said at least one electrical device to said plurality of electrical systems to operate said electric motor in accordance with said algorithm.
9-11. (canceled)
12. The vehicle of claim 1, wherein said engine includes a plurality of parallel external combustion engines equipped with at least one electrical generating element, wherein said plurality of parallel external combustion engines operate simultaneously with said at least one electrical generating element to generate electrical energy, wherein the generated electrical energy is routed through at least one solid state switching device, and wherein electrical energy generated by said generator is routed through said at least one electrical device to said plurality of electrical systems to operate said electric motor in accordance with an algorithm.
13-14. (canceled)
15. The vehicle of claim 8, further comprising: a plurality of electrical storage devices; a solid state switching device; and a controller; wherein electricity generated by the device is directed to said plurality of electrical storage devices for storage by means of said solid state switching device under the control of said controller as directed by said algorithm.
16-18. (canceled)
19. The vehicle of claim 1, further comprising: a series hybrid electric drivetrain; a solid state switching device; and a controller; wherein said generator is in electrical communication with said series hybrid electric drivetrain, and wherein said solid state switching device is wherein said controller is a computerized controller which controls said solid state switching device by way of a software control algorithm.
20-22. (canceled)
23. The vehicle of claim 1, wherein said threshold temperature is a suitable operating temperature for initiating a sustained external combustion cycle selected from the group consisting of Stirling Cycles, Ericsson Cycles, Brayton Cycles, Rankine Cycles and Kalina Cycles.
24. The vehicle of claim 1, wherein said threshold temperature is a temperature at which sufficient motive gas or working fluid is flowing for the rotation of the bladeless turbine by means of the Boundary Layer Effect from expanding combustion gases or steam.
25. The vehicle of claim 1, wherein said controller transitions the engine to an active state when the temperature sensed by said temperature sensor exceeds a predetermined threshold value.
26. The vehicle of claim 25, wherein said controller transitions the engine to an active state by reversing the electrical current flow from the plurality of electrical storage devices to the generator/starter, thereby rotating said shaft and establishing a sustained external combustion cycle, and wherein the motor is operable, while the engine is in an inactive state but after the ignition sequence is initiated, from a first flow of electric energy from the plurality of electrical storage devices to said motor as directed by the algorithm.
27. (canceled)
28. The vehicle of claim 26, further comprising: a thermopile array which derives electrical energy by way of the Seebeck Effect; wherein said motor is operable, while the engine is in an inactive state but after the ignition sequence is initiated, from a second flow of electrical energy from the thermopile array to the motor, and wherein the first and second flows of electrical energy are controlled by said controller as directed by the algorithm.
29. The vehicle of claim 27 wherein, when the engine is in an active state, said controller reverses said first flow of electrical energy from said engine/generator to said electrical storage devices as directed by the algorithm.
30-34. (canceled)
35. The vehicle of claim 1, further comprising: an exhaust conduit, manifold or piping which directs exhaust gases or spent steam away from said engine; a thermopile array configured to extract thermal energy from said exhaust conduit, manifold or piping and to convert said thermal energy into electrical energy by way of the Seebeck effect; a solid state switching device; and a computerized controller which controls the solid state switching device as directed by the algorithm.
36. The vehicle of claim 1, further comprising: a series hybrid-electric drivetrain equipped with a plurality of electrical systems; wherein said plurality of electrical storage devices have sufficient capacity to supply all of the electrical energy demands of the plurality of electrical systems of the series hybrid-electric drivetrain for at least a predetermined minimum period of time under normal operating conditions.
37. The vehicle of claim 1, further comprising: an exhaust conduit, piping or manifold which directs exhaust gases or spent steam away from said engine; a thermopile array configured to extract thermal energy from said exhaust conduit, piping or manifold and to convert said thermal energy into electrical energy by way of the Seebeck effect; a solid state switching device; and a computerized controller which is equipped with a tangible, non-transient medium and which controls the switching device and the shut-down sequence and start-up sequence of the series hybrid-electric drivetrain in accordance with an algorithm recorded in said medium; wherein, upon the initiation of the shutdown sequence, the engine is directed by the algorithm of a computer controller to continue to operate until sufficient electrical energy has been stored in the plurality of electrical storage devices to operate the series hybrid-electric drivetrain through a subsequent start-up sequence.
38. The vehicle of claim 37 wherein, upon completion of the shutdown sequence, any electrical energy subsequently received from the thermopile array is directed to the plurality of electrical storage devices for storage.
39. (canceled)
40. A method for operating a vehicle, comprising: providing an external combustion engine and an electric motor which are mechanically coupled to a drivetrain that includes a rotatable shaft, wherein said external combustion engine is equipped with at least one combustion chamber; providing a temperature sensor which is disposed in said engine and which is in communication with said controller, and wherein said controller maintains the engine in an inactive state until the temperature sensed by said temperature sensor exceeds a predetermined threshold value; providing an energy recovery system comprising a dynamic braking system, a thermopile array and an electrical storage system; imparting motion to said vehicle by driving said drivetrain with said external combustion engine and said electric motor, wherein driving said drivetrain with said external combustion engine generates a stream of exhaust gases or steam; recovering energy from the imparted motion of the vehicle by utilizing the electric motor as a generator when said dynamic braking system is engaged; recovering energy from the operation of the external combustion engine by using said thermopile array to extract thermal energy from said stream of exhaust gases or steam and by converting the extracted thermal energy into electrical energy by way of the Seebek effect; and storing the energy recovered from the motion of the vehicle and from the operation of the external combustion engine in said electrical storage system; receiving a mixture of fuel and air that undergoes combustion in the at least one combustion chamber in accordance with an ignition sequence; and controlling the ignition sequence with a computerized controller which is equipped with a tangible, non-transient medium and which controls the ignition sequence in accordance with an algorithm recorded in said medium.
41-73. (canceled)
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] A better knowledge of the system, the components of the systems, processes and procedures of the present disclosure may be gained by referring to the drawing figures that illustrate particular non-limiting embodiments of the architectures, components, and functions of a scalable configurable point-of-cyber-access cyber system in accordance with the teachings herein.
[0016]
[0017]
[0018]
[0019]
[0020]
DETAILED DESCRIPTION OF THE DISCLOSURE
[0021] While the present invention will be described with reference to preferred embodiments, it will be understood by those who are skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. It is therefore intended that the present invention not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments and legal equivalents thereof as may be comprehended by the claims herein.
[0022] An external combustion engine burns fuel at atmospheric pressure outside the power cylinders of the engine. Thermal energy is transferred to a working fluid or motive gas in the power cylinders by conduction through a heater tube wall or heat exchanger. One example of a rudimentary external combustion engine design is The Stanley Motor Vehicle. By contrast, one of the most advanced external combustion engine designs is the power plant of a nuclear submarine. Despite the sophistication of the latter with respect to the former, the operating principles are the same for both designs. The typical design of an external combustion engine has significantly fewer moving parts than an internal combustion engine, and hence exhibits comparatively lower frictional losses. External combustion engine designs can be based upon various thermodynamic cycles including, for example, the Rankine Cycle, the Stirling Cycle, the Ericsson Cycle, the Brayton Cycle and the Kalina Cycle.
[0023] Combustion of hydrocarbon fuels at atmospheric pressure produces minimal amounts of Oxides of Nitrogen (NO.sub.x) in the emissions of the exhaust gases from external combustion engines. This is true regardless of the variety of the engine, or the thermodynamic cycle upon which it is based. The efficiency of these external combustion cycles, in modern configurations, are typically superior to the efficiency of internal combustion cycles. This result is due, at least in part, to the fact that the external combustion cycle engine is a heat engine where a working fluid or motive gas is contained internally, and derives the thermal energy from chemical combustion or nuclear reaction—external to the motive gas or working fluid—by conduction through the wall of the heater tubes or heat exchanger. The working fluid or motive gas expands in response to the added thermal energy, which then acts upon the mechanism of the engine (usually a piston or turbine) and produces useful mechanical energy. The working fluid or motive gas may then be cooled, compressed and reused in a closed cycle. Alternatively, in an open cycle engine design, the working fluid may be vented, and cool working fluid may be pulled in from a working fluid reservoir.
[0024] The superior efficiency of external combustion engines is due in part to the fact that they have fewer moving parts than internal combustion engines, and thus experience less frictional losses. Additionally, the overall design of the external combustion engine is focused upon the conversion the thermal energy of combustion into work rather than the intermittent explosive force of a fuel/air mixture under compression in a cylinder, as in the internal combustion engine designs. It is for this reason that modern external combustion engines are more efficient than internal combustion engines (for example, those based on the Otto Cycle and Diesel Cycle) currently used in commercially available parallel hybrid designs.
[0025] In the case of employing external combustion to rotate a bladeless turbine, the turbine may derive mechanical energy from the thermal expansion of the gases produced from the combustion of a stoichiometrically balanced fuel/air mixture or steam. The hot expanding gases rotate the discs of the bladeless turbine by means of the boundary layer effect as the hot gases flow in a vortexual pattern toward the exhaust port in the center of the bladeless turbine cylinder casing. Additionally, mechanical energy may be derived from the rotation of the discs in the turbine by employing external combustion cycles such as the Rankine Cycle or the Kalina Cycle. The rotation of the discs can be used to turn an electrical generator(s) to produce electrical energy in a series hybrid-electric drivetrain.
[0026]
[0027]
[0028]
[0029]
[0030]
[0031] Various embodiments of the invention may be equipped with one or more external combustion engines, which may be selected from the group consisting of Rankine Cycle engines, Stirling Cycle engines Ericsson Cycle engines, Brayton Cycle engines and Kalina Cycle engines. These external combustion engines may be mechanically coupled with, and provide mechanical energy to, one or more electrical generators/starters for the production of electrical energy. The electrical energy so produced may then be utilized for the electrical system of a vehicle to provide for useful mechanical energy. The vehicle may be, for example, a vehicle for industrial applications of remote or auxiliary electrical power generation, heavy equipment, a light-duty or heavy-duty vehicle, or a maritime vessel.
[0032] The external combustion engines disclosed herein may employ various thermodynamic cycles including, for example, the Stirling Cycle, the Rankine Cycle, the Ericsson Cycle, the Brayton Cycle, or the Kalina Cycle. Alternatively, these external combustion engines may supply mechanical energy by employing a bladeless turbine. This bladeless turbine may be driven by means of combustion gases or steam. Preferably, the bladeless turbine cylinder is equipped with a plurality of discs, and the bladeless turbine is driven by working fluids which pass along the surfaces of the plurality of discs and induce rotational motion in the turbine by means of the Boundary Layer Effect. The external combustion engine may be operated in a steady state at a fixed rotational speed to achieve optimal thermal efficiency. The rotating shaft of the external combustion engine may be connected to an electrical generator/starter by means of a reduction gear.
[0033] This configuration may be expanded to a plurality of external combustion engines. In such embodiments, all of these external combustion engines may drive generators/starters which may be controlled electronically by a plurality of solid state electrical current regulators such that the electrical cycles and currents are in phase and are balanced from one generator to the next.
[0034] The electrical energy produced by the electrical generator may be connected to one or more solid state switching devices selected from the group consisting of electrical current regulators, insulated gate bi-polar transistors and other solid state switching devices. Electrical energy may be directed to the electrical motor(s) and/or throughout the electrical system in accordance with the algorithm of the computer controller. The electric motor(s) may be used to produce useful mechanical energy which drives one or more rotating shafts to provide useful mechanical energy for heavy equipment, light and heavy-duty vehicles, maritime vessels, or other industrial applications.
[0035] In addition to the generator(s)/starter(s) providing electrical energy to the electric motor(s), the electrical current regulator(s) and/or insulated gate bi-polar transistor(s) and/or other solid state switching device(s), electrical energy may be directed in accordance with the algorithm of the computer controller to provide electrical energy to the other electrical systems including, but not limited to, a plurality of batteries and/or capacitors and/or other devices, to store electrical energy for subsequent use as needed to provide for the variable demands of operation of the external combustion hybrid-electric drivetrain and for the plurality of other electrically powered systems (e.g. fuel pumps, combustion air blowers, compressors, circulating pumps, hydraulic pumps, cooling fans, climate control, lighting, accessories, etc.).
[0036] Exhaust gases and spent steam from the external combustion engine may be directed by means of a manifold, conduit or piping through a plurality of thermopile array(s) where thermal energy from the exhaust gases may be harvested and converted to electricity by means of the Seebeck Effect. The electrical energy derived from a plurality of thermopile array(s) may be routed to the electrical system in accordance with the algorithm of a computer controller through the electrical current regulator(s) and/or insulated gate bi-polar transistor(s) and/or other solid state switching device(s).
[0037] The algorithm of the computer controller may include subroutines that reduce fuel consumption through the application of dynamic braking as well as an all-electric mode of operation when there is no combustion in the external combustion drivetrain, and other low demand operations of the external combustion engine(s).
[0038] While the above description contains certain specifics, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof. Accordingly, the scope of the present invention should be determined not by the embodiment(s) illustrated, but by the claims and their legal equivalents which may herein after be granted upon applications having priority.
[0039] The novel adaptation of the devices and techniques disclosed herein represent an improvement upon the art for surface transportation and industrial applications by adapting external combustion engine drivetrains in a series hybrid-electric configurations to achieve greater thermal efficiency and a significant reduction of emissions of particulate pollution, toxic gases and NO.sub.x compounds.
[0040] The systems, methodologies and devices disclosed herein are applicable to a broad range of applications. These include, without limitation, construction machinery and vehicles such as, for example, articulated trucks, pavers, cold planars, scrapers, compactors, loaders (including, for example, knuckleboom loaders, track loaders, multi-terrain loaders, underground loaders, backhoe loaders, wheel loaders and skid steer loaders), dozers, draglines, drills, rope shovels, excavators, feller bunchers, forest machines, forwarders, harvesters, mining shovels, material handlers, graders, on-highway and off-highway trucks, pipelayers, road reclaimers, tractors, farm tractors, skidders, and telehandlers. These also include aviation ground support vehicles including, for example, re-fuelers, tugs and tractors, ground power units, buses, container loaders, transporters, air start units, water trucks, lavatory service vehicles, catering vehicles, belt loaders, deicing or anti-icing vehicles, and aircraft rescue or firefighting vehicles. These further include trucks such as, for example, box trucks, concrete mixers, dump trucks, flatbeds, semi-tractors, tank trucks and wreckers. These further include merchant vessels such as, for example, dry cargo ships (including bulk carriers and container ships), tankers, coasters and passenger ships.
[0041] The engines disclosed herein may utilize various types of fuel applicators. These include, for example, fuel injectors, fuel vaporizers and fuel atomizers (such as, for example, swirl atomizers).
[0042] The systems and devices disclosed herein may incorporate various electrical components as are known to the art. For example, these systems and devices may require conversion of DC power to AC power, or from AC power to DC power, and may thus incorporate one or more power inverters.
[0043] Various design configurations for Stirling engines may be utilized in the systems, devices and methodologies described herein. These include, but are not limited to, Alpha, Beta, Gamma, and free piston design configurations and variations thereof.
[0044] The vehicles disclosed herein may have various electrical systems, some or all of which may be powered by an electrical motor or by one or more energy storage devices. These include, without limitation, electrical systems selected from the group consisting of electric motors, fuel pumps, air blowers (including, for example, atomizing air blowers, motive air blowers and combustion air blowers), fuel applicators, compressors, circulating pumps, hydraulic pumps, cooling fans, climate control systems, and lighting and electrical accessories.
[0045] The above description of the present invention is illustrative, and is not intended to be limiting. It will thus be appreciated that various additions, substitutions and modifications may be made to the above described embodiments without departing from the scope of the present invention. Accordingly, the scope of the present invention should be construed in reference to the appended claims.