Apparatus and method for combined electrical and mechanical utilization of the energy of an expansion machine

Abstract

An apparatus V and a method, preferably for a motor vehicle, in particular a commercial vehicle. The apparatus V includes an internal combustion engine, an expansion machine and a generator. The expansion machine and the generator can be operatively connected both to one another and in each case to the internal combustion engine via a transmission, in order to make selective electrical utilization and mechanical utilization of the energy of the expansion machine possible.

Claims

1. An apparatus, comprising: an internal combustion engine; an expansion machine; a generator, a transmission configured to operatively connect the expansion machine and the generator to one another and to the internal combustion engine via a transmission to make selective electrical utilization and mechanical utilization of energy of the expansion machine, wherein the generator is connected to a system, the system comprising: an energy store that can be charged by the generator for storing electrical energy; at least one electrical consumer of a motor vehicle; a DC/DC converter configured to supply the on-board power network of the motor vehicle, and a control device configured to controlling the generator.

2. The apparatus according to claim 1, wherein the expansion machine is part of a waste heat utilization system that converts waste heat of the internal combustion engine into utilizable energy by a steam circuit.

3. The apparatus according to claim 1, wherein the expansion machine is part of a waste heat utilization system that converts waste heat of an engine backpressure sure brake system into utilizable energy by a steam circuit.

4. The apparatus according to claim 1, wherein the expansion machine and the generator are configured to be operatively connected both to one another and in each case to a one of: a crankshaft of the internal combustion engine and a power take-off of the internal combustion engine via the transmission.

5. The apparatus according to claim 1, wherein the generator is configured as one of: a) a motor/generator to operate selectively as a generator or as a motor, and b) a pure generator.

6. The apparatus according to claim 1, wherein the system has at least one of the following: a converter configured to supply an on-board power network of the motor vehicle, and an electric motor, via which energy from the energy store is converted into mechanical energy and is made available to the internal combustion engine.

7. The apparatus according to claim 6, wherein the energy store provides electrical energy for at least one of the on-board power network and the at least one electrical consumer.

8. The apparatus according to claim 6, wherein the system is part of at least one of an electrical and an electronic infrastructure of a hybrid drive system that can be installed in the motor vehicle.

9. The apparatus according to claim 1, wherein the generator is operatively connected to the internal combustion engine in at least one of a fixed manner and non-switchable manner.

10. The apparatus according to claim 1, wherein the transmission is configured to at least one of: selectively establish and disconnect the operative connection between the expansion machine and the internal combustion engine, ensure a fixed operative connection between the generator and the internal combustion engine, and ensure a non-switchable operative connection between the generator and the internal combustion engine.

11. The apparatus according to claim 6, wherein the apparatus is configured to operate selectively in at least one of an expander mode, a motor mode, and a generator mode.

12. The apparatus according to claim 11, wherein, in the expander mode, a waste heat utilization system converts waste heat of the internal combustion engine into utilizable energy, the expansion machine generates mechanical energy from the utilizable energy, the mechanical energy being made available to the internal combustion engine via the transmission, and the generator generating electrical energy from the utilizable energy, the electrical energy being made available to the system.

13. The apparatus according to claim 11, wherein, in the generator mode, the generator acts as a generator and the expansion machine generates utilizable energy due to thermal inertia of a waste heat utilization system despite lacking or low thermal input from the internal combustion engine, and the generator generates electrical energy from the utilizable energy of the expansion machine and from mechanical energy of the internal combustion engine, the electrical energy being made available to the system.

14. The apparatus according to claim 11, wherein, in the motor mode, one of the generator acts as a motor and an electric motor of the system acts as a motor, to convert electrical energy that comes from an energy store into mechanical energy and makes the mechanical energy available to the internal combustion engine via the transmission.

15. The apparatus according to claim 11, wherein, during the motor mode, the expansion machine at least one of does not generate any mechanical energy, generates the mechanical energy, and at least begins to generate the mechanical energy, and makes the mechanical energy available to the internal combustion engine via the transmission.

16. The apparatus according to claim 11, wherein, in the motor mode, one of the generator acts as a motor and an electric motor of the system acts as a motor, until an energy store is at least largely emptied and the generator transfers into a generator mode.

17. The apparatus according to claim 11, wherein, in a generator mode, the generator acts as a generator, and the expansion machine generates utilizable energy by thermal input from an engine backpressure brake system, without thermal input from internal engine combustion of the internal combustion engine, and the utilizable energy is stored in an energy store and is made available to the internal combustion engine in a subsequent motor mode.

18. An operating method for an apparatus, having an internal combustion engine, an expansion machine, a generator, a system to which the generator is connected, and a transmission, comprising: charging an energy store of the system by the generator for storing electrical energy; supplying by a DC/DC converter an on-board power network of the motor vehicle, controlling the generator by a control device; and one of: operatively connecting the expansion machine and the generator to one another and the internal combustion engine via the transmission, and operatively connecting at least one of the expansion machine and the generator to the internal combustion engine via the transmission, and selective utilization of electrical and mechanical energy of the expansion machine.

19. A motor vehicle comprising: an apparatus comprising: an internal combustion engine; an expansion machine; a generator, a transmission configured to operatively connect the expansion machine and the generator to one another and to the internal combustion engine via a transmission to make selective electrical utilization and mechanical utilization of energy of the expansion machine, wherein the generator is connected to a system, the system comprising: an energy store that can be charged by the generator for storing electrical energy; at least one electrical consumer of a motor vehicle; a DC/DC converter configured to supply the on-board power network of the motor vehicle, and a control device configured to controlling the generator.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above-described embodiments and features of the invention can be combined with one another. Other advantageous developments of the invention are disclosed in the subclaims or result from the following description of preferred embodiments of the invention in conjunction with the appended figures, in which:

(2) FIG. 1 is an apparatus according to one embodiment of the invention,

(3) FIG. 2 is the apparatus from FIG. 1 in an expander mode,

(4) FIG. 3 is the apparatus from FIG. 1 in a generator mode, and

(5) FIG. 4 is the apparatus from FIG. 1 in a motor mode.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

(6) The concept according to the invention relates to an apparatus and a method which, instead of pure electrical or pure mechanical utilization, make a combined utilization variant of the recuperated expander energy possible.

(7) An apparatus V for combined or selective electrical and mechanical utilization of the energy of an expansion machine 3 is shown in FIG. 1 and is suitable, in particular, for installation in a motor vehicle, expediently commercial vehicle, for example lorry or omnibus.

(8) The apparatus V comprises an internal combustion engine 1 which can preferably be a diesel, petrol, or gas engine for stationary or mobile (on-road, off-road, or marine) applications, or an engine using alternative fuels for the said areas of application. The expansion machine 3 and a motor/generator 4 are installed directly or indirectly on the internal combustion engine 1.

(9) The expansion machine 3 is part of a waste heat utilization system that converts waste heat of the internal combustion engine 1 into utilizable energy again with the aid of a steam circuit, preferably an ORC process.

(10) The motor/generator 4 can be configured as a low voltage (for example, 24 V, 48 V) or high voltage generator (for example, 400 V to 800 V) and, depending on requirements, can operate in a current-generating manner in the Generator operating mode or in a current-consuming manner in the Motor operating mode.

(11) The expansion machine 3 and the generator 4 are operatively connected both to one another and in each case, in particular, to the crankshaft of the internal combustion engine 1 via a transmission 2.

(12) The generator 4 is operatively connected to the internal combustion engine 1 in a fixed/non-switchable manner, with the result that there is expediently a permanent operative connection.

(13) In contrast, the expansion machine 3 is operatively connected to the internal combustion engine 1 such that it can be switched, in particular disconnected, with the result that an operative connection can expediently be established and disconnected, in particular by the transmission 2.

(14) The transmission 2 can consist of a drive and a switching element. The drive of the transmission 2 can be, for example, a single-stage or multiple-stage friction wheel or spur gear stage, expediently without or with at least one intermediate wheel/gear, for example integrated into a wheel/gear drive of the internal combustion engine 1 or arranged separately from the latter. The drive of the transmission 2 can likewise be configured as an external flexible drive (for example, chain or belt drive) or can consist of a combination of different drives.

(15) In a manner dependent on the type of expansion machine 3, the transmission 2 can have, in addition to the drive, at least one clutch or switching element, by way of which the connection between the expansion machine 3 and the internal combustion engine 1 can be disconnected, in order for it not to be necessary to be coupled to the expansion machine 3, for example, during cold starting. The clutch or switching element of the transmission 2 can expediently be active (for example, electrically or hydraulically actuated multiple disc clutch, switchable freewheel, etc.) or passive (for example, clamping body freewheel).

(16) In a manner dependent on the type of expansion machine 3, the transmission 2 can have, in addition to the drive, at least one decoupling element, by way of which the transmission of torsional vibrations between the connected components expansion machine 3-internal combustion engine 1-generator 4 can be suppressed. The decoupling element of the transmission 2 can be, for example, a torsionally elastic connection.

(17) The motor/generator 4 is connected via an electrical/electronic connection 5 (for example, line/lines, interface/interfaces, etc.) to an expediently electrical/electronic system 6 that primarily has the object of storing electrical energy by an energy store 7 and controlling the operating mode of the motor/generator 4 by a control unit. Furthermore, the system 6 can comprise a motor vehicle on-board power network and/or at least one electrical consumer of the motor vehicle and/or be an electrical and/or electronic infrastructure of a hybrid drive system which is installed in the motor vehicle or can be combined with a hybrid drive system.

(18) At relatively high operating voltages of the generator 4 (for example, 48 V), the electrical energy for the on-board power network and the electrical consumers can also be made available at the 24 V voltage level via a DC/DC converter which is preferably integrated into the electrical system 6. As a result, the previous 24 V generator can possibly be dispensed with and the components of expander 3 and motor/generator 4 can be installed into the free installation space in a manner virtually neutral in terms of installation space. In addition, the storage device 7 (for example, 48 V batteries) of the electrical system 6 can replace the large part of the storage capacity of the previous 24 V batteries; a residual capacity on a 24 V basis can remain necessary merely for the starter of the motor vehicle.

(19) As mentioned above, the electrical system 6 can be part of an electrical and/or electronic infrastructure of a hybrid drive system which is installed in the motor vehicle, for example can be replaced by the latter and/or combined with the latter. In this case, the motor/generator 4 can be configured as a pure generator, the conversion and introduction of electrical energy preferably stored in the energy store 7 then taking place via the electric motor of the hybrid drive system which is already installed in the motor vehicle.

(20) The apparatus V is configured to be operated in an expander mode, a generator mode, and a motor mode which can preferably be controlled via a control unit of the electrical system 6.

(21) The method for combined electrical and mechanical utilization of the expander energy comprises a plurality of possible operating states which are controlled via the control unit of the electrical system 6.

(22) FIG. 2 shows the apparatus V in an expander mode.

(23) The Expander mode operating state occurs in that state, in which the internal combustion engine 1 generates drive energy and the waste heat utilization system is in operation for waste heat utilization.

(24) In this operating state, the expansion machine 3 generates mechanical energy and makes it available to the internal combustion engine 1 via the transmission 2. During this, the motor/generator 4 operates in the generator mode and generates the required electrical energy for the system 6, for example the on-board power network and electrical actuators and/or consumers in the motor vehicle.

(25) The energy flow in the expander mode is designed substantially as follows, as depicted in FIG. 2:

(26) Of the 100% energy which is generated by the expansion machine 3, X % is converted into electrical energy via the motor/generator 4 in the generator mode and is made available to the electrical system 6. The remaining (100X) % is available as mechanical energy at the crankshaft of the internal combustion engine 1 or for the internal combustion engine 1. The size of the value X is based on the current power consumption of the motor vehicle.

(27) Advantages over purely electrical or purely mechanical utilization:

(28) Despite electrical utilization, the electrical energy generated is independent of the currently generated expander energy, since the excess flows as mechanical energy to the internal combustion engine 1 in a manner which is optimum in terms of the degree of efficiency.

(29) FIG. 3 shows the apparatus V in a generator mode.

(30) The Generator mode operating state occurs in that state, in which the waste heat utilization system is not yet ready for operation and is in the warm-up phase (for example, after cold starting) or in which the internal combustion engine 1 is in an overrun and/or braking mode.

(31) In the warm-up phase of the waste heat utilization system, the expansion machine 3 does not yet generate any mechanical energy. During this, the motor/generator 4 operates in the generator mode and generates the necessary electrical energy for the system 6, for example the on-board power network and the electrical actuators and/or consumers in the motor vehicle.

(32) In the overrun and/or braking mode of the internal combustion engine 1, the expansion machine 3 still generates utilizable energy, on account of the thermal inertia of the waste heat utilization system, despite the missing thermal input. During this, the motor/generator 4 operates in the generator mode and generates the maximum possible electrical energy made available to the energy store 7 of the system 6.

(33) In the generator mode, it is possible, in particular, that the expansion machine 3 generates utilizable energy, to be precise by heat from an engine backpressure brake system, the heat from the engine backpressure brake system passing indirectly to the expansion machine 3 via the waste heat utilization system. The utilizable energy generated can be stored in the energy store 7 and can be made available to the internal combustion engine 1 in a subsequent motor mode.

(34) The energy flow in the generator mode is designed substantially as follows, as depicted in FIG. 3:

(35) Of the 100% energy generated by the motor/generator 4 in the generator mode, X % comes from the expansion machine 3, and the remaining (100X) % is made available by the internal combustion engine 1 via the transmission 2 which is optimum in terms of the degree of efficiency. The size of the value X is zero during the warm-up operation of the waste heat utilization system.

(36) Advantages over purely electrical or purely mechanical utilization:

(37) In the overrun or braking mode of the internal combustion engine 1, the energy which is stored in the waste heat utilization system on account of the thermal inertia does not have to bypass the expansion machine 3 without being utilized, but rather can be converted into electrical energy and stored in a fruitful manner.

(38) In addition, in the overrun and braking mode of the internal combustion engine 1, energy can preferably be recuperated by way of the motor/generator 4 and can be charged into the energy store 7 of the system 6.

(39) Internal combustion engines 1 in the described applications are often equipped with modern engine braking systems which generate high, hot gas mass flows through the internal combustion engine 1 in the engine braking mode. In the case of purely electrical or purely mechanical utilization of the expander energy of the waste heat utilization system, this is lost to the surroundings via the exhaust gas system, since the generated expander energy cannot be exploited in this operating state. In the case of combined utilization according to the invention, the said heat can be utilized and can be buffer-stored via the motor/generator 4 and the system 6 and utilized again in the following drive phase.

(40) FIG. 4 shows the apparatus V in a motor mode.

(41) The Motor mode operating state occurs in that state, in which the waste heat utilization system is in operation or out of operation and the energy store 7 of the electrical system 6 has been charged completely or else only partially with the aid of the motor/generator 4 in a preceding overrun and/or braking mode of the internal combustion engine 1.

(42) In this operating state, the expansion machine 3 either does not generate any mechanical energy, it generates mechanical energy or it begins to generate mechanical energy again by way of the thermal input into the waste heat utilization system which is again present, and makes the said mechanical energy available to the internal combustion engine 1 via the transmission 2.

(43) During this, the motor/generator 4 operates in the motor mode and also introduces the electrical energy which is removed from the energy store 7 of the system 6 and is converted into mechanical energy into the internal combustion engine 1 via the transmission 2.

(44) The on-board power network and the electrical actuators and/or consumers in the motor vehicle can be supplied by the energy store 7 of the system 6, for example via a DC/DC converter, until the said energy store 7 is emptied and the motor/generator 4 transfers into the generator mode again.

(45) The energy flow is designed substantially as follows, as depicted in FIG. 4:

(46) Of the 100% energy which is made available to the internal combustion engine 1 via the transmission 2, X % comes from the expansion machine 3 and the remaining (100X) % comes from the motor/generator 4 which uses the energy in the energy store 7 of the system 6. If insufficient energy from the waste heat utilization system is available to the expansion machine 3, the size of the value X is zero.

(47) Advantages over purely electrical or purely mechanical utilization:

(48) In the fired mode of the internal combustion engine 1, which follows an overrun and/or braking phase of the internal combustion engine 1, no energy from the expander 3 is directly available, since the waste heat utilization system first of all has to warm up again. Precisely in these fuel-intensive operating states, the energy recuperated and stored in the overrun and/or braking mode of the internal combustion engine 1 can be made available directly to the internal combustion engine 1 via the motor/generator 4 in a manner that reduces the consumption.

(49) It is to be mentioned that the generator 4 does not have to be configured as a motor/generator, but rather can also be configured as a pure generator. In this case, the system 6 can have an electric motor which can assume the motor function of the motor/generator 4.

(50) The system 6 and the electric motor can be part here of a hybrid drive system which is already installed in the motor vehicle.

(51) The invention is not restricted to the above-described preferred embodiments. Rather, a multiplicity of variants and modifications are possible which likewise use the concept of the invention and therefore fall within the scope of protection. Moreover, the invention also claims protection for the subject matter and the features of the subclaims independently of the features and claims referred to.

(52) Thus, while there have shown and described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. Moreover, it should be recognized that structures and/or elements and/or method steps shown and/or described in connection with any disclosed form or embodiment of the invention may be incorporated in any other disclosed or described or suggested form or embodiment as a general matter of design choice. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.