Turbocharger system

Abstract

A turbocharger system for a light or heavy duty vehicle, a maritime vehicle or a construction vehicle comprises a turbocharger device, an exhaust manifold conduit, a valve, a receptacle for compressed gas and a gas compressor for compressing gas. By opening the valve during a predetermined pulse duration time period, compressed gas may be provided from the receptacle to the exhaust manifold conduit for initial turbocharger compressor spin-up. The turbocharger system further comprises a cooling means configured to decrease temperature of compressed gas provided by the gas compressor, and a heating means configured to increase temperature of the gas pulse generated by opening of the valve. By decreasing the temperature of the compressed gas in the receptacle upstream of the valve and subsequently heating up the generated air pulse before being provided to the exhaust manifold conduit, the response time of the turbocharger device can be improved.

Claims

1. A turbocharger system for a vehicle, the turbocharger system comprising: a turbocharger device including a turbocharger compressor and a turbocharger turbine; an exhaust manifold conduit arranged to be in fluid communication with an inlet of the turbocharger turbine; a receptacle for compressed gas arranged to be in fluid communication with the exhaust manifold conduit; a gas compressor for compressing gas and configured to provide compressed gas to the receptacle; a valve arranged between the exhaust manifold conduit and the receptacle, the valve being configured to control a gas flow from the receptacle to the exhaust manifold conduit such that compressed gas from the receptacle may be provided to the exhaust manifold conduit during a predetermined pulse duration time period for initial spin-up of the turbocharger compressor; a cooling means configured to decrease temperature of the compressed gas provided by the gas compressor, wherein the cooling means is arranged between the gas compressor and the valve or at the gas compressor; and a heating means configured to increase temperature of the compressed gas before being provided to the exhaust manifold conduit, wherein the heating means is arranged between the valve and the inlet of the turbocharger turbine.

2. A system for a vehicle, the system comprising: an exhaust manifold; and the turbocharger system according to claim 1; wherein the exhaust manifold is in fluid communication with the exhaust manifold conduit and the receptacle, and wherein the valve and the receptacle are arranged to provide compressed gas to the exhaust manifold during the predetermined pulse duration time period for initial spin-up of the turbocharger compressor.

3. The turbocharger system according to claim 1 wherein the receptacle comprises a tank and at least one pipe, and wherein the tank and the at least one pipe are in direct fluid communication with each other.

4. The turbocharger system according to claim 3 wherein the cooling means comprises one pipe of the least one pipe of the receptacle, wherein the one pipe is arranged between the gas compressor and the tank of the receptacle, such that the compressed gas provided by the gas compressor is able to be cooled down before being provided to the tank.

5. The turbocharger system according to claim 4 wherein the cooling means is formed as a finned heat exchanger that comprises the one pipe of the receptacle, and the finned heat exchanger includes cooling flanges extending from the one pipe in a direction perpendicular to a direction of the one pipe.

6. The system according to claim 2 wherein the heating means is formed as a heat conductive conduit arranged such that at least a portion of the heat conductive conduit is guided along and in contact with a surface of the exhaust manifold or is formed as a heat conductive conduit arranged as at least one channel formed in the exhaust manifold, such that heat may be transferred from the exhaust manifold to the heat conductive conduit of the heating means.

7. The system according to claim 2 wherein the exhaust manifold is a dual sheet manifold, and wherein the heating means is provided by allowing the gas to flow through cavities of the dual sheet manifold.

8. The turbocharger system according to claim 3 wherein one pipe of the at least one pipe of the receptacle is arranged between the gas compressor and the tank of the receptacle, wherein the one pipe allows the gas compressor and the tank to be in fluid communication with each other, wherein the one pipe is provided at an inclined angle such that a first end of the one pipe is arranged to the gas compressor and is elevated in relation to an opposite second end of the one pipe, and wherein the second end of the one pipe is arranged to the tank such that condensate formed in the one pipe and/or the gas compressor is dischargeable to the tank.

9. The turbocharger system according to claim 3 wherein the receptacle further comprises a drainage pipe arranged at a low portion of the tank such that condensate formed in the tank is dischargeable from the tank.

10. The turbocharger system according to claim 1 wherein the valve is configured to have: an opening response time of 25 to 100 ms and a closing response time of 50 to 200 ms.

11. The turbocharger system according to claim 1 wherein the valve is configured to empty 90% of the receptacle within 500 ms.

12. The turbocharger system according to claim 1 wherein the receptacle comprises a tank and a pipe arranged to connect the gas compressor to the tank, wherein the gas compressor is set to be in fluid communication with the tank via the pipe, and the pipe has an inner diameter of 4 to 5 mm.

13. The turbocharger system according to claim 1 wherein the receptacle comprises a tank and a pipe extending from the tank to the valve, wherein a gas flow from the tank through the pipe is controllable by using the valve, and the pipe has an inner diameter of essentially 12 to 15 mm.

14. A vehicle comprising the turbocharger system according to claim 1.

15. The vehicle according to claim 14 further comprising a pneumatic chassis suspension and/or air pressure brake system, and wherein the gas compressor and the receptacle are part of the pneumatic chassis suspension and/or the air pressure brake system.

16. A vehicle comprising the system according to claim 2.

17. The vehicle according to claim 16 further comprising a pneumatic chassis suspension and/or air pressure brake system, and wherein the gas compressor and the receptacle are part of the pneumatic chassis suspension and/or the air pressure brake system.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Below the present disclosure is described in connection with the attached drawings, in which:

(2) FIG. 1 schematically discloses a vehicle comprising a systems in turn comprising a turbocharger system according to one embodiment of the present disclosure;

(3) FIG. 2 schematically discloses an engine comprising a system in turn comprising a turbocharger system according to one embodiment of the present disclosure; and

(4) FIG. 3 schematically discloses an engine comprising a system in turn comprising a turbocharger system according to another embodiment of the present disclosure.

DETAILED DESCRIPTION

(5) As required, detailed embodiments are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary and that various and alternative forms may be employed. The figures are not necessarily to scale. Some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art.

(6) FIG. 1 discloses a vehicle 1 comprising an engine 3, wherein the engine 3 is provided with a turbocharger 20. The engine 3 and the turbocharger 20, and other not explicitly disclosed engine components, are controlled by an engine control unit 4.

(7) FIG. 2 schematically discloses a turbocharger system 10 for a vehicle 1 according to the disclosure. The turbocharger system 10 comprises a turbocharger 20, a receptacle 30 for compressed gas, a valve 70, an exhaust manifold conduit 40 and a gas compressor 80. The turbocharger system 10 is part of a system 11 also comprising an exhaust manifold 60. The turbocharger comprises a turbocharger compressor 21 and a turbocharger turbine 22.

(8) The exhaust manifold conduit 40 is in fluid communication with a turbocharger inlet 50 of the turbocharger 20, wherein the inlet 50 is in fluid communication with the turbocharger turbine 22. The exhaust manifold conduit 40 is further in fluid communication with the exhaust manifold 60. The exhaust manifold 60 is in turn in fluid communication with the receptacle 30. The receptacle 30 is in fluid communication with the gas compressor 80.

(9) When the gas compressor 80 is operating a gas flow is created, originating from the gas compressor 80 and possibly flowing past in order; the receptacle 30, the valve 70 (if open) the exhaust manifold 60, the exhaust manifold conduit 40 to the turbocharger 20. The gas flow is indicated by arrows A.

(10) In the embodiment disclosed in FIG. 2 the receptacle 30 comprises a tank 31 and a first pipe 32, wherein the first pipe 32 is directly connected to be in fluid communication with the tank 31 and wherein the first pipe 32 is arranged downstream of the tank 31 in relation to a gas flow originating from the gas compressor 80 as is indicated by the arrows A.

(11) The first pipe 32 of the receptacle 30 is in fluid communication with the exhaust manifold 60, and via the exhaust manifold 60 to the exhaust manifold conduit 40. Between the receptacle 30 and the exhaust manifold 60, which in the embodiment of FIG. 2 is between the first pipe 32 of the receptacle 30 and the exhaust manifold 60, the valve 70 is arranged. The valve 70 is configured to control a gas flow from the receptacle 30 to the exhaust manifold 60.

(12) In the embodiment of the present disclosure shown in FIG. 2 the total enclosed volume of the receptacle 30 is formed by the volume of the tank 31 and the first pipe 32. In other, not shown embodiments of the present disclosure the receptacle may be formed by just a tank being directly connected to an exhaust manifold/exhaust manifold conduit, wherein a valve is arranged to control the gas flow between the tank of the receptacle and the exhaust manifold/exhaust manifold conduit, such that the tank and the exhaust manifold/exhaust manifold conduit is in fluid communication. For such embodiments the total enclosed volume of the receptacle is the volume of the tank. In yet further, not shown embodiments of the present disclosure the receptacle may be formed by just a pipe, wherein the pipe is fluidly connecting the gas compressor with the exhaust manifold, in the presence of a valve, wherein the total enclosed volume of the receptacle is the volume of the pipe.

(13) The gas compressor 80 is configured to when in operation compress a suitable gas which is temporarily stored in the receptacle 30. By controlling the valve 70, which is controlling the gas flow from the receptacle 30 to the exhaust manifold 60 it is possible to generate a gas pulse by opening the valve 70 during a predetermined duration time period. By opening the valve 70 and thereby injecting a gas pulse into the exhaust manifold 60 the gas flow in the exhaust manifold 60 and thereby in the exhaust manifold conduit 40 is increased. This has the effect that the turbocharger turbine 22 will be spinned-up, increasing the rotational speed of the turbocharger turbine 22. Increasing the rotational speed of the turbocharger turbine 22 will increase the rotational speed of the rotationally coupled turbocharger compressor 21 wherein additional boosting of the engine 1 is achieved. Thus, the turbocharger system 10, or the system 11 comprising the turbocharger system 10, as disclosed in FIG. 2 may be used to improve the response of the turbocharger 20.

(14) However, further improvements of the system 11, further reducing the turbocharger response time is possible by optimizing the system 11.

(15) The embodiment of the turbocharger system 10, and the system comprising the turbocharger system 11, also comprises cooling means 90 and heating means 100.

(16) The cooling means 90 of the embodiment of the present disclosure shown in FIG. 2 comprises a second pipe 33 of the receptacle 30 provided with cooling fins 91. By e.g., guiding an air flow generated when driving the vehicle 1 past the cooling fins 91 of the cooling means 90 the compressed gas provided by the gas compressor 80 flowing through the second pipe 33 to the tank 31 can be cooled down.

(17) The heating means 100 of the embodiment of the present disclosure shown in FIG. 2 comprises that a heat conductive conduit 101 is arranged to the exhaust manifold 60. The thermal energy developed during the combustion of fuel will heat up the exhaust manifold 60, wherein the hot exhaust manifold 60 will heat up the heat conductive conduit 101 of the heating means 100. Heating of the heat conductive conduit 101 will in turn heat up the generated gas pulse flowing through the heat conductive conduit 101.

(18) The cooling means 90 enables that the temperature of the compressed gas is decreased before being fed to the receptacle 30. This has the effect that the pressure of the compressed gas is lowered, wherein the gas compressor 80 can compress and provide more gas to be fed to the receptacle. Thus, the density of the compressed gas is increased.

(19) The heating means 100 subsequently increases the temperature of the generated gas pulse. Increasing the temperature of a gas, such as of the generated gas pulse, will increase the gas pressure and thereby generate an increased gas flow. Thus, by increasing the temperature of the gas of the gas pulse the increase of pressure caused by the gas pulse will be even more significant.

(20) An additional increase of the pressure in the exhaust manifold 60 increasing the gas flow through the exhaust manifold 60, and thereby in the fluidly connected exhaust manifold conduit 40, will provide additional spin-up of the turbocharger turbine 22 and thereby further improve the turbocharger 20 response.

(21) In FIG. 2, is but one example of how a cooling means may be provided and but one example of how a heating means may be provided disclosed. Other possible ways to provide cooling means and heating means are disclosed in the description above.

(22) FIG. 2 discloses that the system 10 comprises an exhaust manifold 60 in fluid communication with the exhaust manifold conduit 40. In FIG. 2, the tank 31 is arranged to push gas into the exhaust manifold 60 during a predetermined pulse duration time period for initial compressor spin up in the turbocharger 20. In FIG. 2 the receptacle 30 comprises a tank 31 and a first pipe 32, wherein the tank 31 is connected to and in fluid communication with the exhaust manifold 60 via the first pipe 32. The tank may however be connected directly to the exhaust manifold conduit via a pipe (not shown) or to any other part of the exhaust manifold system being in fluid communication with the turbocharger.

(23) FIG. 2 discloses a receptacle 30 that is rechargeable by use of a gas compressor 80 for compressing gas into the receptacle 30. The compressed gas is preferably air, exhaust gas or any other suitable gas. The compressed gas is preferably supplied to the gas compressor 80 by a gas supplying means 81. If the compressed gas is air the gas supplying means 81 may be in form of an air filter or like.

(24) FIG. 2 discloses the basic principle of a turbocharger 20, wherein the turbocharger 20 is driven by exhaust gas from an engine 3, and wherein the turbocharger compresses air from an air intake 23 into the engine 3 via an engine inlet 24 and inlet manifold 25 of the engine 3.

(25) When the temperature of the compressed gas of the receptacle 30 is lowered and as the pressure of the receptacle 30 is increased there is an imminent risk that condensate will be formed in concerned components.

(26) FIG. 2 further discloses that the second pipe 33 of the disclosed embodiment of the present disclosure is provided at an inclined angle in relation to a longitudinal direction of the vehicle 1. A first end 34 of the second pipe 33 is arranged to the gas compressor 80 and is elevated in relation to a second end 35 of the second pipe 33, wherein the second end 35 of the second pipe 33 is provided at an opposite end of the second pipe 33 than the first end 34. The second end 35 of the second pipe 33 is arranged to the tank 31 such that condensate formed in the second pipe 33 and/or the compressor 80 is discharged to the tank 31. The tank 31 is further provided with a drainage pipe 36, wherein condensate formed in the compressor 80, the second pipe 33 or the tank 31 may be discharged through the drainage pipe 36.

(27) FIG. 3 discloses another embodiment of the present disclosure identical to the embodiment disclosed in FIG. 2 with one exception; in the embodiment shown in FIG. 3 the heating means 100a, which in the embodiment disclosed in FIG. 3 also is in form of a heat conductive conduit 101a, is shorter than the heat conductive conduit 101 of the heating means 100 of FIG. 2. Using a shorter heat conductive conduit 101a as heating means 100a may entail that the heating effect of the heating means 100a is slightly lower.

(28) The cooling means 90 and the heating means 100, 100a disclosed in FIGS. 2 and 3 are just two examples of respective means. Other approaches, e.g., as is disclosed in the description, are possible in order to reach the desired effect of the cooling means, which is lowering the temperature of the compressed gas such that the gas pressure is reduced, and the heating means, which is to increase the temperature of the generated gas pulse such that the gas pressure is increased.

(29) While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms according to the disclosure. The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. Additionally, the features of various implementing embodiments may be combined to form further embodiments according to the disclosure.